Form P6587

PARTS, OPERATION AND MAINTENANCE MANUAL

for
AIR CHAIN HOIST MODELS*
HL1000K HL1000KR HL1500K
1000 kg (1 ton) 1000 kg (1 ton) 1500 kg (1-1/2 ton)
Spark Resistant

HL2000K HL3000K HL4500K HL6000K

2000 kg (2 ton) 3000 kg (3 ton) 4500 kg (4-1/2 ton) 6000 kg (6 ton)

* Capacities of hoists are in metric tons (1 metric ton = 2,200 lbs.)

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual

contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for
the operation, installation and maintenance of these products.

WARNING
Do not use this hoist for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this hoist in accordance with American National
Standards Institute Safety Code (ASME B30.16) and any other applicable safety codes
and regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Form P6587
Edition 6
May 1997
03531837
© 1997 Ingersoll-Rand Company

1
 TABLE OF CONTENTS

Safety Information
Danger, Warning, Caution and Notice .............................................................................................................................................................. 3
Safety Summary ................................................................................................................................................................................................. 3
Safe Operating Procedures ................................................................................................................................................................................ 4
Warning Tags and Labels ................................................................................................................................................................................... 4

Specifications
Model Code Explanation ................................................................................................................................................................................... 6

Installation
Hoist Checks ...................................................................................................................................................................................................... 7
Hoist Mounting .................................................................................................................................................................................................. 7
Chain Container ................................................................................................................................................................................................. 8
Air System .......................................................................................................................................................................................................... 8
Pendant Control Adjustments ............................................................................................................................................................................ 9
Storing the Hoist ................................................................................................................................................................................................ 9

Operation
Initial Operating Checks .................................................................................................................................................................................. 10
Hoist Controls .................................................................................................................................................................................................. 10
Pendant Controls .............................................................................................................................................................................................. 10
Pull Chain Control ........................................................................................................................................................................................... 11

Inspection
Records and Reports ........................................................................................................................................................................................ 12
Load Chain Reports ......................................................................................................................................................................................... 12
Frequent Inspection ......................................................................................................................................................................................... 12
Periodic Inspection .......................................................................................................................................................................................... 13
Hoists Not in Regular Use ............................................................................................................................................................................... 14
Inspection and Maintenance Report ................................................................................................................................................................ 15

Troubleshooting .............................................................................................................................................................................................. 16

Lubrication
General Lubrication ......................................................................................................................................................................................... 17

Maintenance
Load Chain Care .............................................................................................................................................................................................. 18
Initial Chain Installation .................................................................................................................................................................................. 19
Chain Replacement .......................................................................................................................................................................................... 22
Servicing the Filter and Strainer ...................................................................................................................................................................... 23
Disassembly ..................................................................................................................................................................................................... 23
Cleaning, Inspection and Repair ..................................................................................................................................................................... 25
Assembly .......................................................................................................................................................................................................... 25
Load Test .......................................................................................................................................................................................................... 31

Assembly Drawings and Parts Lists ..................................................................................................................................................... 33 - 61

Assembly Drawing and Parts List Table of Contents ..................................................................................................................................... 32

Parts Ordering Information

Return Goods Policy ........................................................................................................................................................................................ 62
Disposal ............................................................................................................................................................................................................ 62

Warranty Information ................................................................................................................................................................................... 63

Offices and Addresses .................................................................................................................................................................................... 64

2
 SAFETY INFORMATION

This manual provides important information for all personnel The National Safety Council, Accident Prevention Manual for
involved with the safe installation, operation and proper Industrial Operations, Eighth Edition and other recognized
maintenance of this product. Even if you feel you are familiar safety sources make a common point: Employees who work near
with this or similar equipment, you should read this manual cranes or assist in hooking on or arranging a load should be
before operating the product. instructed to keep out from under the load. From a safety
standpoint, one factor is paramount: conduct all lifting
Danger, Warning, Caution and Notice operations in such a manner that if there were an equipment
Throughout this manual there are steps and procedures which, if failure, no personnel would be injured. This means keep out
not followed, may result in a hazard. The following signal words from under a raised load and keep out of the intended path of
are used to identify the level of potential hazard. any load.

Danger is used to indicate the presence Ingersoll-Rand Material Handling hoists are manufactured in
DANGER of a hazard which will cause severe accordance with the latest ASME B30.16 standards.
injury, death, or substantial property
damage if the warning is ignored. The Occupational Safety and Health Act of 1970 generally
places the burden of compliance with the user, not the
Warning is used to indicate the presence manufacturer. Many OSHA requirements are not concerned or
WARNING of a hazard which can cause severe connected with the manufactured product but are, rather,
injury, death, or substantial property connected with the final installation. It is the owner’s and user’s
damage if the warning is ignored. responsibility to determine the suitability of a product for any
particular use. It is recommended that all applicable industry,
Caution is used to indicate the presence trade association, federal, state and local regulations be checked.
CAUTION of a hazard which will or can cause Read all operating instructions and warnings before operation.
minor injury or property damage if the
warning is ignored. Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper rigging
Notice is used to notify people of techniques. See ASME B30.9 for rigging information,
NOTICE installation, operation, or maintenance American National Standards Institute, 1430 Broadway, New
information which is important but not York, NY 10018.
hazard-related.
This manual has been produced by Ingersoll-Rand to provide
Safety Summary dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
WARNING It is extremely important that mechanics and operators be
familiar with the servicing procedures of these products, or like
• Do not use this hoist or attached equipment for lifting, or similar products, and are physically capable of conducting the
supporting, or transporting people or lifting or supporting procedures. These personnel shall have a general working
loads over people. knowledge that includes:
• Powered hoists are designed to provide a 5 to 1 safety 1. Proper and safe use and application of mechanic’s common
factor. The supporting structures and load-attaching devices hand tools as well as special Ingersoll-Rand or
used in conjunction with this hoist must provide adequate recommended tools.
support to handle all hoist operations plus the weight of the 2. Safety procedures, precautions and work habits established
hoist and attached equipment. This is the customer’s by accepted industry standards.
responsibility. If in doubt, consult a registered structural
engineer. Ingersoll-Rand cannot know of, or provide all the procedures
by which product operations or repairs may be conducted and
the hazards and/or results of each method. If operation or
NOTICE maintenance procedures not specifically recommended by the
manufacturer are conducted, it must be ensured that product
• Lifting equipment is subject to different regulations in each safety is not endangered by the actions taken. If unsure of an
country. These regulations may not be specified in this operation or maintenance procedure or step, personnel should
manual. place the product in a safe condition and contact supervisors
and/or the factory for technical assistance.

3
 SAFE OPERATING PROCEDURES

The following warnings and operating instructions have been 11. Do not leave a load suspended for extended periods.
adapted in part from American National (Safety) Standard 12. Always stand clear of the load path.
ASME B30.16 and are intended to avoid unsafe operating 13. Never use the hoist for lifting or lowering people, and
practices which might lead to injury or property damage. never stand on a suspended load.
14. Never carry loads over people.
Ingersoll-Rand recognizes that most companies who use hoists 15. Before each shift, check the hoist for wear or damage.
have a safety program in force in their plants. In the event you Check brakes, limit stops, etc.
are aware that some conflict exists between a rule set forth in 16. Periodically, inspect the hoist thoroughly and replace worn
this publication and a similar rule already set by an individual or damaged parts.
company, the more stringent of the two should take precedence. 17. Follow the lubrication instructions.
18. Do not attempt to repair load chain or hooks. Replace them
Safe Operating Instructions are provided to make an operator when they become worn or damaged.
aware of dangerous practices to avoid and are not necessarily 19. Never operate a hoist when the load chain is not centered
limited to the following list. Refer to specific sections in the under the hook. Do not “side pull” or “yard”.
manual for additional safety information. 20. Always rig the hoist properly and carefully.
21. Ease the slack out of the load chain when starting a lift. Do
1. Only allow personnel instructed in safety and operation on not jerk the hoist load.
this product to operate and maintain the hoist. 22. Keep the load chain clean and well lubricated. Do not drag
2. Only operate a hoist if you are physically fit to do so. the load chain or hook on the floor.
3. When a “DO NOT OPERATE” sign is placed on the hoist 23. Be certain there are no objects in the way of a moving load.
controls, do not operate the hoist until the sign has been 24. Be certain the air supply is shut off before performing
removed by designated personnel. maintenance on the hoist.
4. Read the manufacturer’s operating instructions before 25. Do not swing a suspended load.
operating the hoist. 26. Keep the load block overhead when not in use.
5. Never lift a load greater than the rated capacity of the hoist 27. After use, or when in a non-operational mode, the winch
(unless for test purposes). should be secured against unauthorized and unwarranted
6. Never use the load chain as a sling. use.
7. Never operate the hoist with twisted, kinked, "capsized" or 28. Avoid collision or bumping of hoists.
damaged chain. 29. Pay attention to the load at all times when operating a hoist.
8. Be certain the load is properly seated in the saddle of the 30. Never splice a hoist chain by inserting a bolt between links
hook. or by any other means.
9. Do not use load chain as a ground for welding. Do not 31. Do not force a chain or hook into place by hammering, and
attach a welding electrode to a hoist or sling chain. never insert the point of the hook into a chain link.
10. Do not use the up and down stops as a means of stopping a 32. Do not allow the chain to be exposed to extremely cold
hoist. The up and down stops are emergency devices only. weather. Do not apply loads to a cold chain.

WARNING TAGS AND LABELS

Each hoist is supplied from the factory with the warning tags
and labels shown. If the tags or labels are not attached to your
hoist, order new tags or labels and install. See parts list in parts
section. Read and obey all warnings and other safety
information attached to this hoist. Tags and labels are not shown
actual size.

4
 SPECIFICATIONS

Table 1
Rated No. Speed with Rated Load Speed with Half Load Speed with No Load Hoist
Hoist Capacity Weight*
Chain fpm m/m fpm m/m fpm m/m
Model No.
(kg) Falls up down up down up down up down up down up down lb kgs
HL1000K
1000 26 37 7.9 11.3 31 30 9.4 9.1 40 26 12.2 7.9
HL1000KR 1 84 38.1
HL1500K 1500 16 26 4.9 7.9 22 22 6.7 6.7 28 16 8.5 4.9
HL2000K 2000 13 18 4.0 5.5 15 15 4.6 4.6 20 13 6.1 4.0 125 56.6
2
HL3000K 3000 8 13 2.4 4.0 11 11 3.4 3.4 14 8 4.3 2.4 129 58.5
HL4500K 4500 3 4.6 10 1.4 3.0 7.5 8.4 2.3 2.6 10.5 6.6 3.2 2.0 193 87.5
HL6000K 6000 4 3.5 7.6 1.0 2.3 5.8 6.2 1.8 1.9 8.4 4.8 2.6 1.5 248 112.5
Notes:
* Based on hook mounted hoist with standard 10 ft (3 m) lift and one motor pendant control.
** Performance figures based on 70 SCFM (1.96 cu m/min) at 90 psig (6.3 bar/630 kPa) air supply at hoist inlet. Pendant control
models use approximately 4 SCFM (0.11 cu m/min) more air.

5
Model Code Explanation
Example: HL1000K-2C10-C6S H L 1000K - 2 C 10 - C 6 S
Series: = H
Chain Type:
L = Link
Base Model:
1000K = 1000 kg 1 metric ton (2,200 lbs)
1000KR = 1000 kg 1 metric ton (2,200 lbs) Spark Resistant
1500K = 1500 kg 1-1/2 metric tons (3,300 lbs)
2000K = 2000 kg 2 metric tons (4,400 lbs)
3000K = 3000 kg 3 metric tons (6,600 lbs)
4500K = 4500 kg 4-1/2 metric tons (10,000 lbs)
6000K = 6000 kg 6 metric tons (13,200 lbs)
Control:
0 = No control provided
1 = Pull Chain
2 = Single Motor Pendant
3 = Two Motor Pendant
4 = Three Motor Pendant
Suspension (1):
A = Fixed Lug
B = Bullard Hook (self closing)
C = Swivel Steel Snap Hook
R = Bronze Snap Hook
DA = Plain Rigid Trolley (universal wheels “A” flange)
DD = Plain Rigid Trolley (universal wheels “D” flange)
FXXA (2) = Hand Geared Trolley (universal wheels “A” flange)
FXXD (2) = Hand Geared Trolley (universal wheels “D” flange)
HA = Vane Motor Powered Trolley (universal wheels “A” flange)
HD = Vane Motor Powered Trolley (universal wheels “D” flange)
Length of Lift:
10 = 10 feet (3 metres) Standard
XX = Specify Length
Lower Hook:
B = Bullard Hook (self closing)
C = Steel Snap Hook
R = Bronze Snap Hook
Length of Pull Chain or Pendant Control Hose Drop: *
6 = 6 feet (1.8 metres) Standard
XX = Specify Length (in feet)
Options:
E = Epoxy Paint
M = Manual Release Brake Kit
P = Piped Away Exhaust
S = Steel Chain Container
U = Fabric Chain Container
Compliance with European Machinery Directive: CE adds Pendant Emergency Stop, Main Air Shut Off Valve and
CE =
Overload Protection Device
Notes: (1) Refer to page 58 for Flange Adjustment.
(2) XX = Specify length of hand chain required. Example: "08" = 8 feet, standard.
(3) Order hose lengths in feet. Metric sizes listed for reference only.

6
 INSTALLATION

Prior to installing the hoist, carefully inspect it for possible Trolley Mounted Hoist Installation
shipping damage. Refer to Dwg. MHP0866
Hoists are supplied fully lubricated from the factory. Lubrication When installing a trolley on a beam, measure the beam flange
of the load chain is recommended before initial hoist operation. and temporarily install the trolley on the hoist to determine the
exact distribution and arrangement of the spacers. The total
distance between the wheel flanges should be 3/16 to 1/4 inch (5
CAUTION to 6 mm) greater than the width of the beam flange. The number
of spacers between the trolley side plate and the mounting lug
• Owners and users are advised to examine specific, local or on the hoist must be the same in all four locations in order to
other regulations, including American National Standards keep the hoist centered under the I-beam. The remaining spacers
Institute and/or OSHA Regulations which may apply to a must be equally distributed on the outside of the trolley side
particular type of use of this product before installing or plates.
putting hoist to use.

WARNING NOTICE
• For specific information relating to trolley installation refer
• A falling load can cause injury or death. Before installing, to the manufacturers’ manual supplied with the trolley.
read “SAFETY INFORMATION”.
• The supporting structures and load-attaching devices used HLK Hoist Plain Rigid Trolley
in conjunction with this hoist must provide adequate support
to handle all hoist operations plus the weight of the hoist and
attached equipment. This is the customer’s responsibility. If
in doubt, consult a registered structural engineer.

Hoist Checks
Make certain your hoist is properly installed. A little extra time
and effort in so doing can contribute toward preventing
accidents and helping you get the best service possible.
Always make certain the supporting member from which the
hoist is suspended is strong enough to support the weight of the
hoist plus the weight of a maximum rated load plus a liberal
safety factor.

CAUTION
• Before placing this hoist in service, remove square headed
pipe plug from oil fill hole and replace with hex headed
breather plug attached to caution tag CA210-121.

1. Remove the solid shipping plug located on top of the hoist

and install the attached breather plug prior to using the
hoist.
2. With the hoist placed in its normal level position check that
the gear case oil level is at the check plug on the side of the
gear box.

Hoist Mounting
Hook Mounted Hoist Installation
Place hook over mounting structure. Ensure hook is large
enough to properly fit on structure. Make sure hook latch is
engaged. WARNING
Ensure the supporting member rests completely within the
saddle of the hook and is centered directly above the hook • A minimum of one adjusting spacer must be placed on the
shank. Hoist must freely hang from hook without restriction. outside of the trolley side plates. Ensure correct installation
as described in the parts, operation and maintenance manual
provided with the trolley.
CAUTION
Trolley bolt nuts (207) and (220) torque requirements:
• The supporting member must position on the saddle of the On HL1000K, HL1500K, HL2000K and HL3000K hoists
hook. Ensure hoist does not tilt to one side or the other. torque to 150 ft lbs (203 Nm).
On HL4500K and HL6000K hoists torque to 250 ft lbs (339
Nm).

7
When installing the hoist and trolley on the beam, make certain
the side plates are parallel and vertical. After installation, NOTICE
operate the trolley over the entire length of the beam with rated
load suspended 4 to 6 inches (100 to 150 mm) off the floor. • Always use an air line filter and lubricator with an HLK
hoist.
CAUTION
• To avoid an unbalanced load which may damage the
trolley, the hoist must be centered under the trolley.

NOTICE
• Trolley wheels ride on the top of the lower flange of the
beam.

Ensure beam stops are installed prior to operating hoist and

trolley.

Chain Container
Refer to Dwgs. TPC451-3 and MHP1029 and the
“MAINTENANCE” section for detailed assembly and Air Line Lubricator
disassembly information. Refer to Dwg. MHP0191.
Always use an air line lubricator with these hoists. Use a
NOTICE lubricator having an inlet and outlet at least as large as the inlet
on the hoist motor. Install the air line lubricator as close to the
• Make certain to adjust the container support such that the air inlet on the hoist motor as possible. Refer to
chain container does not contact the load chain or hook. “ACCESSORIES” in the parts section for the recommended
• Operate the hoist to naturally pile chain into the chain Filter-Lubricator-Regulator.
container. Piling the chain carelessly into the container by
hand may lead to kinking or twisting that may cause chain to CAUTION
jam the hoist.
• Lubricator must be located no more than 10 ft (3 metres)
1. Check the chain container size to make sure the length of from the hoist motor.
load chain is within the capacity of the chain container. • Shut off air supply before filling air line lubricator.
Replace with a larger chain container, if required.
2. Attach the chain container to the hoist. The air line lubricator should be replenished daily and set to
3. Run bottom block to lowest point and run hoist in up provide lubrication at a minimum rate of 1 to 3 drops per minute
direction to feed the chain back into the container. adjusted at maximum hoist speed, of SAE 10W oil or a good
grade of hydraulic oil.
WARNING
CAUTION
• Disconnect the hoist from the air supply before installing a
chain container kit. • Do not use automotive type detergent oil. Detergents will
delaminate the motor vanes and cause premature failure.
Air System
The supply air must be clean, lubricated and free from water or Air Line Filter
moisture. A minimum air supply of 70 scfm (1.96 cu. m/m) at 90 Refer to Dwg. MHP0191
psig (6.3 bar/630 kPa) at the hoist motor inlet is required, during It is recommended that an air line strainer/filter be installed as
operation to provide rated hoist performance. close as practical to the motor air inlet port to prevent dirt from
entering the motor. The strainer/filter should provide 10 micron
Air Lines filtration and include a moisture trap. Clean the strainer/filter
The inside diameter of the hoist air supply lines must not be monthly to maintain its operating efficiency. Refer to
smaller than 1/2 in (13 mm) for up to 12 ft (4 m) lengths and 3/4 "ACCESSORIES" in the parts section for the recommended
in (19 mm) for up to 50 ft (15 m) lengths between the air supply Filter-Lubricator-Regulator.
and the hoist. Contact the factory for recommended air line sizes
for distances greater than 50 ft (15 m). Before making final Moisture in Air Lines
connections, all air supply lines should be purged with clean, Moisture that reaches the air motor through the supply lines is
moisture free air before connecting to unit inlet. Supply lines the chief factor in determining the length of time between
should be as short and straight as installation conditions will service overhauls. Moisture traps can help to eliminate moisture.
permit. Long transmission lines and excessive use of fittings, Other methods, such as an air receiver which collects moisture
elbows, tees, globe valves, etc. cause a reduction in pressure due before it reaches the motor or, an aftercooler at the compressor
to restrictions and surface friction in the lines. Fittings used at that cools the air prior to distribution through the supply lines,
the inlet of the hoist must have at least a 3/8 in (10 mm) air are also helpful.
passage. Use of smaller fittings will reduce performance.
The swivel inlet assembly (includes items 23 through 24C) must
be installed on the hoist. Failure to do so may result in a hoist
malfunction.

8
Pendant Control Adjustments For maximum performance and control, adjust the bleed screws
The bleed adjustment screws (19) or (336 [old style]) used on (19) or (336 [old style]) as follows:
hoists with a pendant control are factory adjusted to provide 1. Loosen the adjustment screw locknut (21) or (337 [old
optimum control at 90 psig (6.3 bar/630 kPa) air pressure. If the style]).
hoist is used with other air supply pressures, the bleed 2. Turn the adjustment screw (19) or (336 [old style])
adjustment screws may require readjustment. counterclockwise approximately one third (1/3) of a turn.
3. Fully depress the pendant throttle lever (165) and hold in
depressed position. Turn the adjustment screw clockwise
until the piston rod fully retracts. This adjustment will
provide a good balance of spotting control and maximum
hoist speed. If better spotting control is desired, slowly
back out the adjustment screw a little at a time until the
spotting control is suitable.
4. When adjustment is complete, hold the adjustment screw in
position and tighten the adjustment screw locknut (21) or
(337 [old style]).
5. Repeat steps 1 through 4 for opposite pendant throttle
lever.

Storing the Hoist

1. Always store the hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the load chain, hook pins and hook latch.
4. Place in a dry location.
5. Plug hoist air inlet port.
6. Before returning hoist to service follow instructions for
‘Hoists not in Regular Service’ in the “INSPECTION”
section.

9
 OPERATION

The four most important aspects of hoist operation are: 8. Raise and lower a light load to check operation of the hoist
1. Follow all safety instructions when operating hoist. brake.
2. Allow only people instructed in safety and operation on this 9. Check hoist operation by raising and lowering a load equal
product to operate hoist. to the rated capacity of the hoist 4 to 6 inches (100 to 150
3. Subject each hoist to a regular inspection and maintenance mm) off the floor.
procedure. 10. Check operation of limit devices.
4. Be aware of the hoist capacity and weight of load at all 11. Check to see that the hoist is directly over the load. Do not
times. lift the load at an angle (side pull or “yard”).
12. Check to see that the hoist is securely connected to the
overhead crane, monorail, trolley or supporting member.
WARNING 13. Check to see that the load is securely inserted in the hook,
and that the hook latch is engaged.
• Do not use this hoist for lifting, supporting or transporting
people or lifting or supporting loads over people.
WARNING
• The hook latch is intended to retain loose slings or devices
under slack conditions. Hook latches are not intended to be
an antifouling device, so caution must be used to prevent the
latch from supporting any of the load.

Hoist Controls
Pendant Controls
The HLK hoist can be supplied with an optional manual pull
chain control or a one, two or three function pendant depending
on application. For detailed information on these products refer
to Ingersoll-Rand Manual Form Number P6778 or contact your
nearest distributor or the factory.
Operation of the hoist is the same for all pendants listed in this
section:
1. To lift a load, depress the hoist pendant raise lever.
2. To lower a load depress the hoist pendant lower lever.
3. To throttle lift or lowering speed, regulate the amount the
pendant lever is depressed. Depress lever completely for
maximum speed; depress lever partially for slower speeds.
Operators must be physically competent. Operators should have
no health condition which might affect their ability to react, and 4. To stop lift or lowering function, release the lever. Lever
will spring return to off and hoist motor will stop.
they must have good hearing, vision and depth perception. The
hoist operator must be carefully instructed in his duties and must
Single Function, Two Lever Pendant
understand the operation of the hoist, including a study of the
manufacturer’s literature. The operator must be aware of proper Refer to Dwg. MHP0427.
The two lever pendant is the standard pendant supplied with the
methods of hitching loads and should have a good attitude
regarding safety. It is the operator's responsibility to refuse to HLK and is designed to provide hoist operation only. Hoist
operation must correspond to the directions indicated by the
operate the hoist under unsafe conditions.
arrows located on the pendant levers.
Initial Operating Checks
Hoists are tested for proper operation prior to leaving the
factory. Before the hoist is placed into service the following
initial operating checks should be performed.
1. After installation of trolley mounted hoists, check to ensure
the hoist is centered below the trolley.
2. Check for air leaks in the supply hose and fittings to
pendant, and from pendant to manifold.
3. When first running the hoist or trolley motors a small
amount of light oil should be injected into the inlet
connection to allow good lubrication.
4. When first operating the hoist and trolley it is
recommended that the motors be driven slowly in both
directions for a few minutes.
5. Operate the trolley along the entire length of the beam.
6. Inspect hoist and trolley performance when raising, moving
and lowering test load(s). Hoist and trolley must operate
smoothly and at rated specifications prior to being placed in
service.
7. Check that trolley (if equipped) and hook movement is the
same direction as arrows or information on the pendant (Dwg. MHP0427)
control.

10
Two Function, Four Lever Pendant Pull Chain Control
The four lever pendant is designed to provide a single station for The pull chain provides the operator with a local hoist operating
control of hoist and trolley operations. station. The following operating directions are as viewed from
Refer to Dwg. MHP1008 for pendant lever function and hose to the motor end of hoist, facing the pull chains.
component connections. 1. To lift a load pull down on the right pull chain.
2. To lower a load pull down on the left pull chain.
3. To throttle lift or lowering speed regulate the distance the
pull chain travels. Pull chain to full travel for maximum
speed; pull chain partially for slower speeds.
4. To stop lift or lowering of load, release the pull chain.
Hoist motor will stop.

Three Function, Six Lever Pendant

The six lever pendant is designed to provide a single station for
control of the hoist, the trolley and a third related component
(bridge/runway) operation.
Refer to Dwg. MHP1009 for pendant lever function and hose to
component connections.

11
 INSPECTION

2. HOOKS. Check for wear or damage, increased throat

WARNING width, bent shank or twisting of hook. Replace hooks
which exceed the throat opening and/or saddle dimension
• All new, altered or modified equipment should be inspected discard widths specified in Table 2 (refer to Dwg.
and tested by personnel instructed in safety, operation and MHP0040) or exceed a 10° twist (refer to Dwg.
maintenance of this equipment to ensure safe operation at MHP0111). If the hook latch snaps past the tip of the hook,
rated specifications before placing equipment in service. the hook is sprung and must be replaced. Replace Bullard
• Never use a hoist that inspection indicates is damaged. Burnham hooks if the gate no longer contacts the hook tip.
Refer to Dwg. MHP0662. Refer to the latest edition of
Frequent and periodic inspections should be performed on ASME B30.10 “HOOKS” for additional information.
equipment in regular service. Frequent inspections are visual Check hook support bearings for lubrication or damage.
examinations performed by operators or service personnel and Ensure they swivel easily and smoothly.
include observations made during routine equipment operation.
Periodic inspections are thorough inspections conducted by
personnel trained in the safety, operation and maintenance of
this equipment. ASME B30.16 states inspection intervals
depend upon the nature of the critical components of the
equipment and the severity of usage.
The inspection intervals recommended in this manual are based
on intermittent operation of the hoist eight hours each day, five
days per week, in an environment relatively free of dust,
moisture and corrosive fumes. If the hoist is operated almost
continuously or more than eight hours each day, more frequent
inspections will be required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel trained in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety
hazard must be decided, and the correction of noted safety
hazards accomplished and documented by written report before
placing the equipment in service.

Records and Reports

Inspection records, listing all points requiring periodic
inspection should be maintained for all load bearing equipment.
Written reports, based on severity of service, should be made on
the condition of critical parts as a method of documenting
periodic inspections. These reports should be dated, signed by
the person who performed the inspection, and kept on file where
they are readily available for review.

Load Chain Reports

Records should be maintained documenting the condition of
load chain removed from service as part of a long-range load
chain inspection program. Accurate records will establish a
relationship between visual observations noted during frequent
inspections and the actual condition of the load chain as
determined by periodic inspection methods.

Frequent Inspection
On hoists in continuous service, frequent inspection should be
made by operators at the beginning of each shift. In addition,
visual inspections should be conducted during regular operation
for any damage or evidence of malfunction (such as abnormal
noises).
1. OPERATION. Check for visual signs or abnormal noises
(grinding etc.) which could indicate a potential problem.
Make sure controls function properly and return to neutral
when released. Check load chain feed through the hoist and
bottom block. If chain binds, jumps, is excessively noisy or
"clicks", clean and lubricate the chain. If problem persists,
replace the chain. Do not operate the hoist until all
problems have been corrected.

12
3. UPPER AND LOWER LIMIT DEVICE. Test operation
with no load slowly to both extremes of travel. Upward
travel must stop when the bottom block or stop ring on
chain hits hoist limit arm. Downward travel must stop when
the loop at the unloaded end of the chain decreases and
activates the limit arm.
4. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair
any leaks found. Check and clean the filter in the inlet stud
(24) and the inlet strainer (24C) if equipped.
5. CONTROLS. During operation of hoist, verify response to
pendant, or pull chain, is quick and smooth. Ensure that the
controls return to neutral and hoist operation stops when 8. LOAD CHAIN REEVING. Ensure welds on standing links
released. If hoist responds slowly or movement is are away from the powered chain wheel. Reinstall chain if
unsatisfactory, do not operate hoist until all problems have necessary. On hoists with multiple chain falls, make sure
been corrected. load chain is not capsized, twisted or kinked. Adjust as
6. HOOK LATCH. Make sure the hook latch or gate is required.
present and operating. Replace if necessary.
Periodic Inspection
Frequency of periodic inspection depends on the severity of
CAUTION usage:
• Do not use hoist if hook latch or gate is missing or damaged.
NORMAL HEAVY SEVERE
7. LOAD CHAIN. Examine each link for bending, cracks in yearly semiannually quarterly
weld areas or shoulders, traverse nicks and gouges, weld
splatter, corrosion pits, striation (minute parallel lines) and Disassembly may be required for HEAVY or SEVERE usage.
chain wear, including bearing surfaces between chain links Keep accumulative written records of periodic inspections to
(refer to Dwg. MHP0102). Replace a chain that fails any of provide a basis for continuing evaluation.
the inspections. Check chain lubrication and lubricate if Inspect all the items in "Frequent Inspection". Also inspect the
necessary. Refer to ‘Load Chain’ in “LUBRICATION” following:
section. 1. FASTENERS. Check all rivets, split pins, capscrews and
nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage,
CAUTION distortion, deformation and cleanliness. If external evidence
indicates the need, disassemble. Check gears, shafts,
• The full extent of load chain wear cannot be determined by bearings, sheaves, chain guides, springs and covers.
visual inspection. At any indication of load chain wear Replace worn or damaged parts. Clean, lubricate and
inspect chain and chain wheel in accordance with reassemble.
instructions in ‘Load Chain’ listed in “Periodic Inspection”
section.

Table 2
Throat Width (with Latch installed)
Hoist Standard Bronze Bullard Burnham
Model New Hook Discard Hook New Hook Discard Hook New Hook Discard Hook
in mm in mm in mm in mm in mm in mm
HL1000K and
1.12 28.4 1.21 30.7 1.06 26.9 1.14 29.0 1.37 34.8 1.48 37.6
HL1500K
HL2000K 1.06 26.9 1.14 29.0 1.50 38.1 1.62 41.1
1.50 38.1 1.62 41.1
HL3000K
1.50 38.1 1.62 41.1 1.87 47.5 2.02 51.3
HL4500K 1.75 44.5 1.89 48.0
HL6000K 1.75 44.5 1.89 48.0 2.75 69.9 2.97 75.4 3.00 76.2 3.24 82.3

Saddle Dimension
Hoist Standard Bronze Bullard Burnham
Model New Hook Discard Hook New Hook Discard Hook New Hook Discard Hook
in mm in mm in mm in mm in mm in mm
HL1000K and
1.12 28.4 1.21 30.7 1.44 36.6 1.56 39.6 1.34 34.0 1.45 36.8
HL1500K
HL2000K 1.44 36.6 1.56 39.6 1.50 38.1 1.62 41.1
1.81 46.0 1.95 49.5
HL3000K
1.81 46.0 1.95 49.5 1.87 47.5 2.02 51.3
HL4500K 2.25 57.2 2.43 61.7
HL6000K 2.25 57.2 2.43 61.7 2.97 75.4 3.21 81.5 2.75 69.9 2.97 75.4

13
3. HOOKS. Inspect hooks carefully for cracks using magnetic Table 3 Load Chain Length
particle or other suitable nondestructive method. Inspect
hook retaining parts. Tighten or repair, if necessary. Dimensions Of Link Discard
Number Of
4. LOAD CHAIN WHEELS. Check for damage or excessive Nominal Wire Length
Pitch Links
wear. Replace if necessary. Observe the action of the load Diameter (n)
(t) (n)
chain feeding through the hoist. Do not operate a hoist (d) Links
unless the load chain feeds through the hoist and hook
block smoothly and without audible clicking or other 1.012 in 5.175 in
3/8 5
evidence of binding or malfunctioning. 25.7 mm 131.4 mm
5. MOTOR. If performance is poor, disassemble the motor
and check for wear or damage to bearings and shafts. The
Zinc plated load chain is standard on HLK hoists built after
parts should be cleaned, lubricated and reassembled.
Replace worn or damaged parts. January 1996. Always use stainless steel load chain on
6. BRAKE. Raise a load equal to the rated capacity of the HL1000KR Spark Resistant Hoists.
hoist 4 to 6 inches (100 to 150 mm) off the floor. Verify
12. CHAIN CONTAINER. Check for damage or excessive
hoist holds the load without drift. If drift occurs,
wear and that chain container is securely attached to the
disassemble. Remove brake discs as described in the
hoist. Secure or replace if necessary.
“MAINTENANCE” section. Check and clean the brake
13. LIMIT ASSEMBLY. Check throttle lever moves freely. To
parts each time the hoist is disassembled. Replace the brake
limit hook downward travel the loop in the slack chain side
discs if the thickness is less than 0.090 inch (2.29 mm).
must contact the throttle lever. To limit hook upward travel
7. SUPPORTING STRUCTURE. Check for distortion, wear
the bottom hook block, or stop ring, must contact the
and continued ability to support load.
throttle lever.
8. TROLLEY (if equipped). Check that the trolley wheels
To test “UP” and “DOWN” travel limits first run hoist
track the beam properly and clearance between each wheel
slowly with no load to verify proper function. Repeat test at
flange and beam is correct, 3/32 to 1/8 in. (2 to 3 mm).
full speed with no load to verify proper function. On Hoist
Check that wheels and beam are not excessively worn.
Models HL4500K and HL6000K the throttle lever (35)
Inspect side plates for spreading due to bending. Do not
may require minor adjustment to provide adequate
operate the hoist until any problems have been determined
clearance with the upper suspension block.
and corrected.
9. LABELS AND TAGS. Check for presence and legibility.
Replace if necessary. Hoists Not in Regular Use
10. LOAD CHAIN END ANCHORS. Ensure both ends of load 1. A hoist which has been idle for a period of one month or
chain are securely attached. Secure if loose, repair if more, but less than one year, should be given an inspection
damaged, replace if missing. conforming with the requirements of “Frequent Inspection”
11. LOAD CHAIN. Measure the load chain for wear over a prior to being placed into service.
five link section as shown in Dwg. MHP1291. Pay 2. A hoist which has been idle for a period of more than one
particular attention to the most frequently reeved links. year should be given an inspection conforming with the
When any five links in the working length reaches or requirements of “Periodic Inspection” prior to being placed
exceeds the discard length shown in Table 3, replace the into service.
entire chain. Always use a genuine Ingersoll-Rand 3. Standby hoists should be inspected at least semiannually in
Material Handling replacement chain. accordance with the requirements of “Frequent Inspection”.
In abnormal operating conditions hoists should be
inspected at shorter intervals.

(Dwg. MHP1291)

14
 INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand HLK Air Chain Hoist
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
Operating Environment:
1. Scheduled Periodic Inspection:
____ Quarterly ____Semiannually ____Yearly _____ Normal _____ Heavy _____ Severe
2. Discrepancy(ies) noted during Frequent Inspection
3. Discrepancy(ies) noted during maintenance
4. Other: ____________________________

Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Refer to appropriate National Standards and
Codes of practice. If in doubt about an existing condition contact the nearest Ingersoll-Rand Distributor or the factory for technical assistance.

CORRECTIVE
CONDITION
COMPONENT ACTION NOTES
Pass Fail Repair Replace
Fasteners
Gears
Shafts
Bearings ---
Load Bearing Sheaves
Chain Guides
Springs ---
Covers
Hooks:
Actual Hook Throat Width: __________ inches / __________ mm (Refer to Table 2 for minimum/maximum acceptable widths.)
Top Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: _____ Dye Penetrant _____ Magnetic Particle _____ Other: ____________________
Actual Hook Throat Width: __________ inches / __________ mm (Refer to Table 2 for minimum/maximum acceptable widths.)
Bottom Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: _____ Dye Penetrant _____ Magnetic Particle _____ Other: ____________________
Hook Latch (Standard) ---
Hook Gate (Bullard) ---
Brakes
---
(10% Load Test)
Brakes
(Visual Inspection)
Tail Pin (End Anchor)
Load Chain: ---
Working length(s) maximum wear: __________ inches / __________ mm (Refer to Table 3)
Supporting Structure
Labels and Tags ---
Other Components
(list in NOTES section)

Testing: Pass Fail NOTES

Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load *)

* Refer to the Parts, Operation, and Maintenance Manual ‘Load Test’ in the “MAINTENANCE” section to determine Maximum Test Load.
This page may be photocopied and used by inspectors or maintenance personnel.

15
 TROUBLESHOOTING

This section provides basic troubleshooting information. Specific causes to problems are best identified by thorough inspections
performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to
common hoist symptoms, probable causes, and remedies.

SYMPTOM CAUSE REMEDY

Hoist will not No air supply to hoist, or too little Check air supply line connections and hoses. Check supply air at hoist motor
operate. flow or pressure. inlet. A minimum of 70 scfm (1.96 cu. m/m) air flow at 90 psig (6.3 bar/630 kPa)
at hoist motor inlet is required to provide rated performance.
Hoist is overloaded. Reduce load to within rated capacity.
Motor is damaged. Disassemble, inspect and replace parts. Refer to “MAINTENANCE” section.
Pendant malfunction. Check pendant throttle lever for free movement. Check air pressure at pendant.
Minimum operating pressure in pendant line must be 55 psig (3.8 bar/380 kPa).
Check lubricator oil level. Fill if low.
Brake not releasing. Check brake release circuit and pressure. Minimum operating pressure at brake
inlet must be 55 psig (3.8 bar/380 kPa).
Load continues to
Valve or throttle lever sticking. Check pendant throttle lever for free movement. Lubricate or repair as required.
move when hoist is
stopped (UP Dump valves not releasing. Check pendant hose dump valves.
direction).
Pendant lever sticking. Check pendant throttle lever for free movement.
Load continues to
move when hoist is Dump valves not releasing. Check pendant hose dump valves.
stopped (DOWN Hoist is overloaded. Reduce load to within rated capacity.
direction).
Valve or throttle lever sticking. Check pendant throttle lever for free movement.
Brake is slipping. Check brake springs and brake disc linings for wear. Refer to “MAINTENANCE”
section.
Hoist does not lift No air supply to hoist, or too little Check air supply line connections and hoses. Check supply air at hoist motor
load. flow or pressure. inlet. A minimum of 70 scfm (1.96 cu. m/m) air flow at 90 psig (6.3 bar/630 kPa)
at hoist motor inlet is required to provide rated performance.
Hoist is overloaded. Reduce load to within rated capacity.
Main air travel is restricted. Check throttle lever and linkage for free, unobstructed movement.
Exhaust restricted. Inspect vents and replace mufflers. Refer to “MAINTENANCE” section.
Motor is damaged. Disassemble, inspect and replace parts. Refer to “MAINTENANCE” section.
Reduced speed Inlet stud (24) screen plugged, Replace old style inlet stud with screen with new style (without screen), or
and/or capacity. restricting air flow. remove screen.
Lubricator oil level low. Fill lubricator.
No air supply to hoist, or too little Check air supply line connections and hoses. Check supply air at hoist motor
flow or pressure. inlet. A minimum of 70 scfm (1.96 cu. m/m) air flow at 90 psig (6.3 bar/630 kPa)
at hoist motor inlet is required to provide rated performance. Check pendant
control adjustment as described in the “INSTALLATION” section.
Bleed screws out of adjustment. Adjust bleed screws as described in ‘Bleed Screw Adjustment’ procedure in
“INSTALLATION” section.
Hoist operates in Hoist is overloaded. Reduce load to within rated capacity.
LOWER direction Pendant malfunction. Check pendant throttle lever for free movement. Check air pressure at pendant.
but will not LIFT. Minimum operating pressure in pendant line must be 55 psig (3.8 bar/380 kPa).
Hoist operates in Brake piston seals leaking. Install new seals. Refer to “MAINTENANCE” section.
LIFT direction but No air supply to hoist, or too little Check air supply line connections and hoses. Check supply air at hoist motor
will not LOWER. flow or pressure. inlet. A minimum of 70 scfm (1.96 cu. m/m) air flow at 90 psig (6.3 bar/630 kPa)
at hoist motor inlet is required to provide rated performance.
Load chain jumps Dirty or lack of oil on load chain. Clean and lubricate load chain. Refer to “LUBRICATION” section.
on sheave or makes Worn or rusted load chain. Inspect load chain. Refer to “INSPECTION” section. Clean and lubricate load
a “snapping” chain. Refer to “LUBRICATION” section.
sound.
Worn load sheave or incorrectly Check load chain is correctly reeved. Disassemble, inspect and replace worn
reeved load chain. parts. Refer to “MAINTENANCE” section.
Capsized hook. Correct as described in “MAINTENANCE” section.
Hoist not in-line with load. Align hoist with load. Do not side pull or “yard”.

16
 LUBRICATION

To ensure continued satisfactory operation of the hoist, all 4. The top and bottom hooks are supported by thrust bearings.
points requiring lubrication must be serviced with the correct These bearings must be packed with Ingersoll-Rand No.
lubricant at the proper time interval as indicated for each 68 grease or a standard No. 2 multipurpose grease at
assembly. Correct lubrication is one of the most important regular intervals. Neglect of proper lubrication will lead to
factors in maintaining efficient operation. bearing failure.

The lubrication intervals recommended in this manual are based In Line Lubricator
on intermittent operation of the hoist eight hours each day, five Lubricate the motor with Ingersoll-Rand Pneu-Lube® Medium
days per week. If the hoist is operated almost continuously, or Oil No. 10 (or SAE 10), or No. 50 (SAE 20 or 20W) non-
more than the eight hours each day, more frequent lubrication detergent motor oil from an in-line lubricator. The use of
will be required. The lubricant types and change intervals are detergent oil may cause premature failure.
based on operation in an environment relatively free of dust,
moisture, and corrosive fumes. Use only those lubricants Load Chain
recommended. Other lubricants may affect the performance of
the hoist. Approval for the use of other lubricants must be
obtained from your Ingersoll-Rand Technical Support WARNING
Department or distributor. Failure to provide proper lubrication
may result in damage to the hoist and/or its associated • Failure to maintain clean and well lubricated load chain
components. will result in rapid load chain wear that can lead to chain
failure which can cause severe injury, death or substantial
property damage.
INTERVAL LUBRICATION CHECKS
Start of each Check flow and level of air line lubricator 1. Lubricate each link of the load chain weekly. Apply new
shift (1 to 3 drops per minute) when operating lubricant over existing layer.
(Operator) hoist at maximum motor speed. 2. In severe applications or corrosive environments, lubricate
more frequently than normal.
Weekly Clean and lubricate load chain. 3. Lubricate hook and hook latch pivot points with same
(Maintenance lubricant used on the load chain.
personnel) Lubricate hook latch and pivot points.
4. If required, clean chain with acid free solvent to remove
Monthly Inspect and clean or replace air line filter. rust or abrasive dust buildup and lubricate the chain.
(Maintenance 5. Use Ingersoll-Rand LUBRI-LINK-GREEN® or a SAE 50
personnel) to 90 EP oil.

Yearly Drain and replace housing oil. Hook and Suspension Assemblies
(Maintenance 1. Lubricate the hook and hook latch pivot points. Hook and
personnel) latch should swivel/pivot freely.
2. Use Ingersoll-Rand LUBRI-LINK-GREEN® or a SAE 50
to 90 EP oil.
Note: Intervals are based on hoist operation in a normal 3. On HL4500K and HL6000K hoists lubricate the idler
environment as described in the “INSPECTION” section. In wheel bearings (107) in the upper suspension housing
HEAVY or SEVERE operating conditions adjust lubrication (101) and lower hook block (123) with Ingersoll-Rand No.
intervals accordingly. 68 Grease or a good quality No. 2 multipurpose grease.
4. On HL4500K and HL6000K hoists after each 300 hours of
General Lubrication operation or more frequently if hoist is operating in a
Whenever a Series HLK Hoist is disassembled for overhaul or contaminated atmosphere, inject 2 or 3 shots of grease from
replacement of parts, lubricate as follows: a grease gun into grease fittings (111) in the end of the idler
1. Coat all motor parts with a light film of Ingersoll-Rand wheel shafts (110).
Pneu-Lube® Medium Oil No. 50 or a good quality
hydraulic oil before assembling. Housing
Remove the oil level plug from the side of the housing (1). If the
oil level is below the tapped hole, remove the vent plug and add
CAUTION a sufficient amount of Ingersoll-Rand No. 62 oil (Texaco
Meropa No. 3 or Texaco Meropa No. 220). Reinstall the oil
• Do not use automotive type detergent oil. Detergents will level plug and vent plug.
delaminate the motor vanes and cause premature failure.
Other System Components
2. Apply a coating of Ingersoll-Rand No. 70 Grease or Refer to the “LUBRICATION” section in the manufacturer’s
multipurpose grease to the throttle shaft bearings (2) before manual provided with the system component for lubrication
assembly. requirements.
3. Fill the gear case to the level plug on the side of the
housing (1) with Ingersoll-Rand No. 62 oil, or Texaco
Meropa No. 220. Replace oil level plug and vent plug after
filling.

17
 MAINTENANCE

2. Never disassemble the hoist any further than is necessary to

WARNING accomplish the needed repair. A good part can be damaged
during the course of disassembly.
• Never perform maintenance on the hoist while it is 3. Never use excessive force when removing parts. Tapping
supporting a load. gently around the perimeter of a cover or housing with a
• Before performing maintenance, tag controls: soft hammer, for example, is sufficient to break the seal.
DANGER - DO NOT OPERATE - 4. Do not heat a part with a flame to free it for removal, unless
EQUIPMENT BEING REPAIRED. the part being heated is already worn or damaged beyond
• Only allow personnel instructed in service and repair of this repair and no additional damage will occur to other parts.
hoist to perform maintenance.
• After performing any maintenance on the hoist, In general, the hoist is designed to permit easy disassembly and
dynamically test hoist to 100% of its rated capacity, in assembly. The use of heat or excessive force should not be
accordance with ASME B30.16 standards, before returning necessary.
hoist to service. Testing to more than 100% of rated capacity
may be required to comply with standards and regulations 5. Keep the work area clean to prevent dirt and other foreign
set forth in areas outside of the USA. matter from getting into bearings and other moving parts.
• Shut off air system and depressurize air lines before 6. All seals, gaskets and ‘O’ rings should be discarded once
performing any maintenance. they have been removed. New seals, gaskets and ‘O’ rings
should be used when assembling the hoist.
Maintenance Intervals 7. When grasping a part in a vise, always use leather or
The maintenance interval chart is based on intermittent copper covered vise jaws to protect the surface of the part
operation of the hoist eight hours each day, five days per week, and help prevent distortion. This is particularly true of
in an environment relatively free of dust, moisture and corrosive threaded members, machined surfaces and housings.
fumes. If the hoist is operated almost continuously or more than 8. Do not remove any part which is press fit in or on a
eight hours each day, more frequent maintenance should be subassembly unless the removal of the part is necessary for
performed. repairs or replacement.
9. To avoid damaging bearings during hoist assembly or
INTERVAL MAINTENANCE CHECK disassembly always tap or press on the bearing inner race
for shaft fit bearings or the outer race for bore fit bearings.
Start of each shift Make a thorough visual inspection of the
10. If repair work can only be conducted above body height,
(Operator or hoist for damage. Do not operate the hoist if suitable working platforms or ladders should be made
Maintenance damaged. available.
Personnel) Operate the hoist in both directions. Hoist
must operate smoothly without sticking, Load Chain Care
binding or abnormal noises. Check the Keep the chain well lubricated as instructed in the
operation of the brake. “LUBRICATION” section. Never operate a hoist when the load
chain does not flow freely and smoothly into and out of the
Semiannually Inspect the brake. Clean or replace parts as chain wheel(s), or when it makes noises indicative of binding or
(Maintenance required. Adjust brake as necessary. other malfunctions.
Personnel) If the chain is visibly damaged replace the chain and examine
Yearly Inspect the hoist gearing, shafts and bearings the chain wheel and chain guard. Install a new chain wheel if the
(Maintenance for wear and damage. Repair or replace as old one is visibly worn. Install a new guard if the old one is
Personnel) necessary. broken or distorted.
Refer to “INSPECTION” section for information on load chain
Check all the supporting members, including inspection.
the suspension, fasteners, nuts, sheaves and
rigging, etc. for indications of damage or
wear. Repair or replace as required. CAUTION
• The full extent of load chain wear cannot be determined by
General Maintenance Instructions visual inspection. At any indication of load chain wear
All maintenance work performed on the hoist must be recorded inspect chain and chain wheel. Refer to “INSPECTION”
with the date in the inspection report. section.

Proper use, inspections and maintenance increase the life and The standard chain provided with this hoist is case hardened to a
usefulness of your Ingersoll-Rand equipment. During assembly, depth of 0.010 to 0.012 inch (0.25 to 0.35 mm). When the outer
lubricate gears, nuts, capscrews and all machined threads with hardened case layer is worn through, additional wear will
applicable lubricants. Use of antiseize compound and/or thread progress rapidly and the strength of the chain will be
lubricant on capscrew and nut threaded areas prevents corrosion considerably reduced.
and allows for ease of disassembly of components. Additionally, the chain will no longer fit the pockets in the hoist
chain wheel properly causing the chain wheel to wear rapidly.
It is recommended that all maintenance work on the hoist be This will greatly increasing the chance of hoist malfunction and
performed on a bench in a clean, dust free work area. During the chain breakage.
process of disassembling the hoist, observe the following: The hoist chain wheel is designed to outlast several chain
1. Turn off air system and depressurize air lines before replacement cycles if the chain is replaced as recommended.
performing any maintenance. Disconnect air line from
hoist.

18
Initial Chain Installation
The following instructions apply to hoists that do not have load
chain installed. For hoists with load chain installed, that must be
replaced, refer to the ‘Chain Replacement’ section. When
directed to remove or install hoist sections or subassemblies to
assist in chain installation, refer to the applicable ‘Disassembly’
or ‘Assembly’ section for specific requirements.

HL1000K, HL1000KR and HL1500K

The following steps describe the initial installation of chain on
single fall hoists that do not have load chain installed.
1. Remove the brake spring and piston housing, brake discs
and brake plates to expose the brake driver.
2. From the side of the chain wheel opposite the chain anchor
bolt, engage the first link of load chain in a pocket of the
chain wheel on edge. Refer to Dwg. TPA706-4, ‘Chain
Installation - Step 1.’ The weld on the load chain link must
face away from the powered chain wheel. Refer to Dwg.
MHP0472.
3. Rotate the brake driver by hand to feed the load chain
through the hoist.

5. Attach free end of load chain to hook. Inspect chain while

operating hoist slowly. Ensure chain feeds through chain
wheel smoothly, without sticking or binding. Repeat
operation in the opposite direction.

HL2000K and HL3000K

The following steps describe the initial installation of chain on
double fall hoists that do not have load chain installed.
1. Complete steps 1 through 4 of “HL1000K, HL1000KR and
HL1500K Chain Installation” section. Refer to MHP0472,
TPA706-4, and TPA706-3.

WARNING
• Replacement chain for an HLK double fall hoist must have
an ODD number of total links. Refer to Dwg. MHP0441.

(Dwg. TPA706-4)

4. Keep the load chain straight and do not twist it. Attach the
free end of the load chain to the connecting link. Refer to
Dwg. TPA706-3, ‘Chain Installation - Step 2.’ Clean,
inspect and install the brake spring, brake discs, brake
plates and piston housing on hoist.

2. Ensure the chain is straight and feed the end through the
bottom hook chain wheel with the first link on edge with
the weld to the inside of the idler chain wheel. Refer to
Dwg. TPA706-2, ‘Chain Installation - Step 3.’

19
 HL4500K and HL6000K
The following steps describe the initial installation of chain on
three or four fall hoists that do not have load chain installed.
1. Remove the brake spring and piston housing, brake discs
and brake plates to expose the brake driver.
2. Place the edge of the first link of load chain in a pocket of
the hoist powered chain wheel. Refer to Dwg. MHP0472.
3. Ensure the chain is straight and attach the free end to the The weld on the load chain link must face away from the
chain anchor bracket. Refer to Dwg. TPA706-1, ‘Chain powered chain wheel pocket.
Installation - Step 4.’
CAUTION
• Improper installation of the load chain will cause
premature wear of the chain wheels resulting in damaged
equipment, which can cause injury or property damage.

3. Rotate the brake driver by hand to feed the load chain

through the hoist in the direction of the dead end chain
anchor (raise direction).
4. Keep the load chain straight, do not twist it. Attach the free
end of the load chain to the connecting link. Refer to Dwg.
TPA1056 for HL4500K and Dwg. TPA1057 for HL6000K.
Clean and inspect the brake parts and assemble.
5. On HL6000K hoists, slide the limit stop tube onto the load
chain.
6. Keeping the load chain straight, complete the load chain
installation as described in either the HL4500K or
HL6000K ‘Hoist Load Chain Reeving’ section.

HL4500K Hoist Load Chain Reeving

Refer to Dwg. TPA1056.
After the load chain has been correctly installed onto the hoist
powered chain wheel it must be carefully routed through the
lower block idler chain wheel, the upper suspension idler chain
wheel and secured to the bottom block housing as described in
4. Inspect to ensure chain is not twisted, kinked or “capsized”. this section.
Refer to Dwg. MHP0020 and MHP0043.
WARNING
• Twisted load chain can jam as it passes over the chain
wheel causing damage to the hoist or breaking the load chain
which can cause injury or property damage.

1. Raise the bottom hook block to a position near the hoist

where it can be properly supported and restrained from
movement.
2. Ensure the load chain remains straight. Feed load chain
through bottom block idler chain wheel.

20
 5. Lubricate the load chain as described in the
NOTICE “LUBRICATION” section. Operate the hoist fully in both
directions without a load attached. Hoist must operate
• The load chain links that were standing links on the smoothly without sticking, binding or chain ‘jumping’. Test
powered chain wheel are also standing links on the bottom hoist completely as described in the ‘Testing’ section
block idler chain wheel. before returning to general service.

3. Ensure the load chain remains straight. Feed the chain HL6000K Hoist Load Chain Reeving
through the upper suspension idler chain wheel. Refer to Dwg. TPA1057.
After the load chain has been correctly installed onto the hoist
powered chain wheel it must be carefully routed through the
NOTICE lower block idler chain wheel, the upper suspension idler chain
wheel and secured to the housing as described in this section.
• The load chain links that were standing links on the
powered chain wheel and bottom block chain wheel are flat
links on the upper suspension idler chain wheel. WARNING
• Twisted load chain can jam as it passes over the chain
wheel causing damage to the hoist or breaking the load chain
which can cause injury or property damage.

1. Raise the bottom hook block to a position near the hoist

where it can be properly supported and restrained from
movement.

(Dwg. TPA1056)

4. Ensure the load chain remains straight. Feed the load chain
through the upper suspension idler chain wheel and insert
end link into bottom block load end chain anchor. Do not
twist the load chain when attaching it to the load end chain
anchor. If necessary cut the last link from the load chain
(refer to Dwg. MHP0441) and remove it to prevent
twisting. Secure in place using anchor pin.

(Dwg. TPA1057)
NOTICE
2. Ensure the load chain remains straight. Place the limit stop
• The bottom block assembly may require adjustment to tube on the load chain and feed load chain through bottom
ensure it is level with an equal number of load chain links
block idler chain wheel.
along the length of each load bearing fall. To level out the
bottom block assembly feed the load chain through the
bottom block and upper suspension idler chain wheels as
necessary to ‘balance’ the bottom block assembly. Ensure the
powered chain wheel does not turn during adjustment.

21
 1. Raise the hoist hook (HL1000K, HL1000KR, HL1500K) or
NOTICE hook block (HL2000K, HL3000K, HL4500K, HL6000K)
to a position near the hoist where it can be properly
• The load chain links that are standing links on the powered supported and restrained from movement.
chain wheel must also be standing links on the bottom block 2. Disconnect the load chain load end link from either the
idler chain wheel. hook (HL1000K, HL1000KR, HL1500K) or the load end
chain anchor (HL2000K, HL3000K, HL4500K,
3. Ensure the load chain remains straight. Feed the chain HL6000K). On the HL2000K and HL3000K, remove the
through the upper suspension idler chain wheel. load chain from the bottom block.
3. Using an abrasive wheel, cut a section from the end link to
form a ‘C’ link, as shown in Dwg. MHP0502.
NOTICE
• The load chain links that are standing links on the powered CAUTION
chain wheel and bottom block chain wheel must be flat links
on the upper suspension chain wheel. • Do not distort the link in any manner. It must be able to
pass over the chain wheel(s) without binding.
4. Ensure the load chain remains straight. Feed the load chain
through the second bottom block idler chain wheel. Insert
end link into upper suspension load end chain anchor. Do
not twist the load chain when attaching it to the load end
chain anchor. If necessary cut the last link from the load
chain (refer to Dwg. MHP0441) and remove it to prevent
twisting. Secure in place using anchor pin.

NOTICE
• The bottom block assembly may require adjustment to 4. Connect the new chain to the old chain by inserting the end
ensure it is level with an equal number of load chain links of the new chain onto the ‘C’ link. Make certain the welds
along the length of each load bearing fall. To level out the and links on the new chain match the positioning of the
bottom block assembly feed the load chain through the welds and links on the chain being replaced.
bottom block and upper suspension idler chain wheels as 5. The following hoist specific instructions describe the steps
necessary to ‘balance’ the bottom block assembly. Ensure the that must be taken to complete the load chain replacement
powered chain wheel does not turn during adjustment. on your hoist.

5. Lubricate the load chain as described in the HL1000K, HL1000KR and HL1500K Chain Replacement
“LUBRICATION” section. Operate the hoist fully in both Complete the initial steps described in ‘Chain Replacement’.
directions without a load attached. Hoist must operate Conduct the following additional steps on single fall hoists to
smoothly without sticking, binding or chain ‘jumping’. Test complete load chain replacement installation.
hoist completely as described in the ‘Testing’ section 1. Slowly operate the hoist in the raise direction to run off the
before returning to general service. old chain and reeve the new chain over the chain wheel.
Refer to Dwg. TPA706-4.
Chain Replacement
The following instructions describe the replacement of load
chain on hoists with chain installed. If the load chain has been NOTICE
removed, it must be reinstalled or replaced as described in the
‘Initial Chain Installation’ section. When directed to remove or • The first link of new chain over the powered chain wheel
install hoist sections or subassemblies to assist in chain must be a standing link.
installation, refer to the applicable ‘Disassembly’ or ‘Assembly’
section for specific requirements. 2. After the new chain has been reeved over the powered
chain wheel, remove the old chain and the ‘C’ link. Secure
the dead end of the load chain to the dead end chain anchor
CAUTION located on the hoist. Refer to Dwg. TPA706-3. Make
certain the load chain is not twisted between the chain
• Damaged load chain may cause chain wheel wear or wheel and dead end chain anchor.
damage and result in hoist failure, injury or property 3. Lubricate the load chain. Refer to “LUBRICATION”
damage. Worn or damaged load chain must be removed, the section.
hoist and bottom block assemblies disassembled and the 4. Rotate the last link in the load chain such that it is
powered and idler chain wheels inspected before continuing perpendicular to the next link with the weld facing down,
hoist operations. towards the hook. Refer to parts Dwg. MHP1105. Attach
• Do not attempt to replace load chain with hoist supporting the hook to the load end of the load chain. Operate the hoist
a load. Remove all loads. slowly in both directions. Hoist must operate smoothly,
• The following procedures use powered hoist operations. without sticking or binding.
Extreme care must be taken to ensure safe operating
conditions exist to prevent injury and hoist or property HL2000K and HL3000K Chain Replacement
damage when operating hoist. Complete the initial steps described in ‘Chain Replacement’.
Conduct the following additional steps on double fall hoists to
Load chain replacement for all hoist models can be complete load chain replacement installation.
accomplished efficiently and easily by using the existing load 1. Slowly operate the hoist in the raise direction to run off the
chain to install the new load chain. old chain and reeve the new chain over the chain wheel.
Refer to Dwg. TPA706-4.

22
 5. Run the hook up and down several times under power with
NOTICE no load to ensure the load chain is running smoothly over
the chain wheels. There must be no apparent binding or
• On double chain fall hoists the total number of load chain evidence of malfunctioning.
links must be an ODD number. Ensure the new load chain
has an odd number of total chain lengths. Refer to Dwg. Servicing the Filter and Strainer
MHP0441. 1. Disconnect the air supply from the hoist.
• The first link of new chain over the powered chain wheel 2. Unscrew the air hose from the inlet strainer (24C).
must be a standing link. 3. Unscrew the inlet strainer from the inlet body (23).
4. Clean the screen inside the inlet strainer by washing with a
2. After the new chain has been reeved over the powered quality, non-toxic, nonflammable commercial solvent in a
chain wheel, remove the old chain and the ‘C’ link. Secure well ventilated area. If the screen is damaged or cannot be
the dead end of the load chain to the dead end chain anchor cleaned, replace the inlet strainer.
located on the hoist. Refer to Dwg. TPA706-3. Make 5. Unscrew the inlet stud (24) from the valve chest (6) and
certain the load chain is not twisted between the chain remove the inlet stud and inlet body from the valve chest.
wheel and dead end chain anchor. 6. Push the inlet stud out of the inlet body.
3. Reeve the load end of the load chain around the bottom 7. Remove the two swivel inlet seals (24A) from the inlet
block idler chain wheel. Ensure the chain is not twisted stud.
between the hoist chain wheel and the bottom block chain 8. If the swivel inlet gasket (24B) is damaged, replace it.
wheel. Refer to Dwg. TPA706-2. 9. If hoist is equipped with a filter inside the inlet stud, clean
4. Ensure the load chain remains straight and attach the load by washing with a quality, non-toxic, nonflammable
end of the load chain to the chain anchor bracket located on commercial solvent in a well ventilated area. If the filter
the hoist. Refer to Dwg. TPA706-1. cannot be cleaned, replace the inlet stud. (New style inlet
5. Lubricate the load chain. Refer to “LUBRICATION” studs do not have filters).
section. 10. Moisten the new swivel inlet seals with ‘O’ ring lubricant
6. Operate the hoist slowly in both directions. Hoist must and install them in the grooves around the body of the inlet
operate smoothly, without sticking or binding. stud.
11. Push the inlet stud into the inlet body until the 'hex' of the
HL4500K and HL6000K Chain Replacement stud is flush against the face of the inlet body.
Complete the initial steps described in ‘Chain Replacement’. 12. Keep the threaded hole of the inlet body facing away from
Conduct the following additional steps on three and four fall the hoist and screw the inlet stud into the valve chest.
hoists to complete load chain replacement installation. Refer to 13. Screw the inlet strainer into the inlet body.
Dwg. TPA1056 for HL4500K hoists and TPA1057 for 14. Screw the air hose into the inlet strainer.
HL6000K hoists. 15. Reconnect the air supply to the hoist.
1. Keeping the new load chain straight, slowly operate the
hoist in the raise direction to run off the old load chain and Disassembly
reeve the new load chain over the powered and idler chain
wheels.
WARNING
NOTICE • Disconnect the air supply hose before performing any
maintenance or repairs on this hoist.
• Make certain the welds and links on the new chain match
the positioning of the welds and links on the chain being Refer to ‘General Maintenance Instructions’ and also note:
replaced. The new chain must be installed such that as it is 1. The HLK hoist is constructed of various modules. During
reeved through the hoist the first link of new load chain over the process of disassembly it is not always necessary to
the powered chain wheel will be a standing link with the weld disassemble a particular module just because it is removed
facing away from the powered chain wheel. from the hoist. For example, the valve chest assembly must
be removed (as an assembly) to access and disassemble the
2. After the new load chain is reeved over the powered chain motor. However, the valve chest need not be disassembled
wheel, remove the old chain from the dead end chain unless parts within the valve chest require replacement. Do
anchor at the side of the hoist and attach the end of the new not disassemble the hoist any further than necessary to
chain. Ensure the load chain is not twisted between the replace or repair damaged parts.
powered chain wheel and the dead end chain anchor. 2. Do not disassemble this hoist unless you have a complete
set of new gaskets, ‘O’ rings and seals on hand for
WARNING replacement. These are available in overhaul gasket kit No.
HLK-K445. Idler wheel seals (108) and hook pins (130)
• Twisted load chain can jam as it passes over the chain are not included in the kit and must be ordered separately.
wheels, damaging to the hoist and possibly breaking the 3. Do not attempt to wash sealed bearings.
chain resulting in injury and property damage.
New Style Valve Chest Disassembly
3. Keep the load end of the load chain straight, attach the load This procedure describes the disassembly of valve chests used
end link to the load end chain anchor located in the bottom on hoists with the second letter of the Serial Number other than
block (HL4500K) or in the upper suspension housing A through G, or with second and third letters of the Serial
(HL6000K). Do not twist the chain when attaching it to the Number other than HA, HB or HC. Replacement part numbers
load end chain anchor. If necessary cut the last link from are listed in the parts section. Refer to Dwg. TPA958-1.
the load chain and remove it to prevent twisting. Refer to 1. On hoists with pendant control, disconnect the three
Dwg. MHP0441. pendant hoses (171) from the fittings (181) and (182).
4. Lubricate the load chain. Refer to the “LUBRICATION” Remove the valve chest plate screw (30) and disconnect the
section. strain relief cable (175).
2. Remove the pendant links (183).

23
3. Unscrew the valve chest screws (26) and (27) and remove 2. Remove the brake plates (78) and brake discs (79) from the
the valve chest (6) and valve chest gaskets (25). gear case cover. Remove ‘O’ ring (air port) (77) and
4. Unscrew and remove the swivel inlet assembly. Push the discard.
inlet stud (24) out of the inlet body (23) to expose the 3. Disassemble the spring and piston housing as follows:
swivel inlet seals (24A). a. Remove the plate screws (88) and the plate (87).
5. Unscrew the valve chest cover screws (22) and remove the b. Place the assembly, pressure plate (82) downward, on
valve chest cover (18) and valve chest cover gasket (16). an arbor press, or; place the assembly vertically in a
6. Remove the piston and piston shaft assemblies (14 and 15) vise.
and piston springs (13). c. While holding the housing against the compression of
7. Remove the valve seat lock screws (11). the springs (81), hold the pressure plate screw (82A)
8. While exerting pressure against the valve seats (10), use with a wrench and unscrew the piston nut (82B).
retainer ring pliers to remove the valve seat retainers (12). d. Relax the tension of the compressed springs (81) by
9. Using a hooked tool, pull the valve seats from the valve slowly and carefully easing up on the arbor press or
chest or rap the bottom of the valve chest on a block of vise.
wood. e. Remove the pressure plate and push the piston (83)
10. Remove the valve assemblies (7) and (8) and valve springs from the housing. Remove ‘O’ rings (84) and (85) and
(9) from the valve chest. discard.
11. If the piston shaft seals (15A) require replacement, press 4. To remove the brake driver (73), remove retainer screw
the piston retaining pins (15B) from each piston and shaft (76) and brake seal retainer (74). Slide brake driver off
and slide the pistons off the shafts. motor shaft (38). Remove brake seal (75) and discard.

Old Style Valve Chest Disassembly Motor Disassembly

This procedure describes the disassembly of valve chests used Refer to Dwgs. TPA958-1 and TPB703-3.
on hoists with second letter of the Serial Number A through G 1. Remove the brake mechanism. Refer to ‘Brake
or with second and third letters of the Serial Number HA, HB, Disassembly’ section.
or HC. Refer to Dwg. TPA883-3. 2. Drain oil from the gear case.
3. Remove the valve chest (6) as an assembly. Refer to
applicable (new or old style) valve chest disassembly
NOTICE section.
4. Remove the limit actuator retaining pin (34) and withdraw
• Replacement parts for this valve chest are no longer the limit actuator (33).
available. Order kit No. MLK-K545B (03835519) to replace 5. Unscrew the remaining valve chest plate screws (30) and
this style valve chest if it cannot be repaired. remove the valve chest plate (28).
6. Grasp the rear end plate (41) and pull the motor from the
1. On a hoist with pendant control, disconnect the three hoist as an assembly. If the motor is a little “sticky”, tap on
pendant hoses (171) at the elbows (181) and (182). Remove the brake end of the motor shaft (38) with a soft drift to
the valve chest plate screw (30) and disconnect the strain loosen.
relief cable (175). 7. Grasp the motor shaft vertically in copper-covered vise
2. Unscrew and remove the inlet strainer (24C). jaws.
3. Unscrew the valve chest screws (26) and (27) and remove 8. Remove the motor shaft rear retaining ring (39).
the assembled valve chest and valve chest gaskets (25). 9. Separate the rear end plate (41), rear end plate bearing (40),
4. Unscrew and remove the swivel inlet assembly. Slide the cylinder (44), cylinder dowel (45), vanes (43), rotor (42),
inlet stud (24) out of inlet body (23) to expose the swivel front end plate (46) and front end plate bearing (47) into
inlet seal (24A). component parts.
5. Unscrew the valve chest cover capscrews (339), and
withdraw the valve chest cover (334) along with the piston Disassembly of the Gearing, Pocket Wheel, Chain Guide,
rods (328) and (329), pistons (330) and piston springs Chain Guard, and Throttle Shaft
(333). Remove the valve chest cover gasket (338). Refer to Dwgs. TPB705-2 and MHP1065.
6. Withdraw the two valves (325) and the two valve springs
(327).
NOTICE
NOTICE • When assemblies are separated into component parts the
exposed ‘O’ rings and gaskets should be discarded and
• Valves (325) and sleeves are manufactured as a matched replaced with new during assembly.
set. Do not mix valves and sleeves. Ensure the valves are
marked for sleeve location at disassembly. 1. Remove the brake mechanism. Refer to ‘Brake
Disassembly’ section.
Brake Disassembly 2. Remove the motor. Refer to ‘Motor Disassembly’ section.
Refer to Dwg. TPB704-3. 3. Remove the four gear case capscrews (70) and lockwashers
1. Unscrew the four shoulder bolts (89) and lockwashers (90) (71). Remove the gear case cover (69). It may be necessary
and separate the springs (81) and piston housing (80) as an to use a slide hammer puller attached to a bar and fastened
assembly from the gear case cover (69). to two of the brake cover bolt holes.
4. Remove the gear case cover gasket (66) and discard.
NOTICE 5. If required, separate the fixed ring gear (67) from the gear
case cover (69) by gently prying the ring gear from the
• When assemblies are separated into component parts the cover, or by removing the ring gear pins (68). Discard the
exposed ‘O’ rings and gaskets should be discarded and ring gear pins and replace with new.
replaced with new during assembly. 6. Withdraw the planet frame (54) and gears as an assembly.
The planet frame may then be disassembled.

24
7. Do not remove the needle roller bearings (63A) or (58) Clean all hoist component parts in solvent (except for the brake
from the planet frame or planet gears unless required for discs). Care must be taken to clean components thoroughly, but
repair. If removed they must be discarded and replaced with not damage components during cleaning. The use of a stiff
new sets. bristle brush will facilitate the removal of accumulated dirt and
8. Drive out the throttle lever retaining pin (36) from the sediments on the gears and frames. If bushings have been
throttle shaft (32). removed it may be necessary to carefully remove old Loctite®
9. From the motor end of the hoist, withdraw the throttle shaft from the bearing bores without damaging the mating surfaces.
(32) and remove the throttle lever (35), throttle lever thrust Dry each part using low pressure, filtered compressed air.
washers (36A) and throttle shaft spring (37).
10. Withdraw the ring gear (52), powered chain wheel (51A), Inspection
ring gear bearing (50) and planet frame bearing (63C). All disassembled parts should be inspected to determine their
11. Remove the four chain guide capscrews (4A), lockwashers fitness for continued use. Pay particular attention to the
(4B) and the chain guide (4). following:
12. Remove the chain guard (5). 1. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
Chain Container 3. Inspect shafts for ridges caused by wear. If ridges caused
Fabric Chain Container Disassembly by wear are apparent on shafts, replace the shaft.
Refer to Dwg. TPC451-3 4. Inspect all threaded items and replace those having
1. Run bottom block to lowest point to remove chain from damaged threads.
container. Disconnect hoist from air supply. 5. Measure the thickness of the brake discs (79). If the brake
discs are less than 0.090 in. (2.23 mm) replace the brake
discs (79) as a set.
WARNING 6. Check mufflers (20) and (31) for damage or excessive dirt.
7. Check bearings for rotation and wear. Replace if bearings
• Disconnect the hoist from the air supply before removing do not rotate smoothly, without sticking or binding, or if
chain container. bearings are damaged or excessively worn.
8. Inspect brake driver bearing wear area on brake driver (73)
1. Separate connecting link (91) and remove support chain and in planet gear frame (54) for ridges or galling. If either
(306). condition exists replace parts.
2. Remove nuts (303), lockwashers (304) and bracket bolts
(302) connecting mounting bracket (301) to hoist. Repair
3. Remove container as an assembly from hoist. Actual repairs are limited to the removal of small burrs and
4. If further disassembly is required, refer to Dwg. TPC451-3 other minor surface imperfections from gears and shafts. Use a
to separate the assembly into its component parts. fine stone or emery cloth for this work.
1. Worn or damaged parts must be replaced. Refer to the
Metal Chain Container HLK-K750 Disassembly applicable parts listing for specific replacement parts
Refer to Dwg. MHP1029 information.
1. Run bottom block to lowest point to remove chain from 2. Inspect all remaining parts for evidence of damage.
container. Disconnect hoist from air supply. Replace or repair any part which is in questionable
condition. The cost of the part is often minor in comparison
WARNING with the cost of redoing the job.
3. Smooth out minor nicks, burrs, or galled spots on shafts,
bores, pins, or bushings.
• Disconnect the hoist from the air supply before removing
4. Examine all gear teeth carefully, and remove nicks or
chain container.
burrs.
5. Polish the edges of all shaft shoulders to remove small
2. Remove bracket (317) from chain container by removing
nicks which may have been caused during handling.
bolts (322), lockwashers (316) and nuts (303).
6. Remove all nicks and burrs caused by lockwashers.
3. Remove chain container from hoist by removing bolts
7. Replace all seals, ‘O’ rings and gaskets.
(324), lockwashers (325) and nuts (326).
4. To separate the bracket (317) from end link of load chain,
drive out pin (34). NOTICE
5. To remove stop ring (319), remove setscrew (321) and pin
(320) from stop ring. Slide stop ring off of chain. • When assemblies are separated into component parts
discard all exposed ‘O’ rings and gaskets and replace with
Cleaning, Inspection and Repair new during assembly.
Use the following procedures to clean, inspect, and repair the
components of the hoist. Assembly
The following assembly instructions are for a complete assembly
Cleaning of the hoist component modules. Conduct those assembly steps
necessary to reassemble the hoist from the point of which your
CAUTION disassembly ended. For example: if the brake was removed as an
assembly to access the hoist gears, it is not necessary to
completely reassemble the brake to reinstall. Conduct only the
• Bearings that are loose, worn or rotate in the housing must
steps necessary to reattach the brake assembly to the hoist.
be replaced. Failure to observe this precaution will result in
additional component damage.
General Instructions
• Do not use trichloroethylene to clean parts.
Refer to ‘General Maintenance Instructions’ and also:
1. The HLK Hoist is constructed of various modules. The
following instructions will first describe how to assemble
the individual modules and finally, how to assemble a
complete hoist from the assembled modules.

25
2. Always press against the stamped end of a needle-type
bearing when installing the bearing in a bearing recess.
3. Always clean and wipe every part (except the brake parts)
with a thin film of oil before installation.
4. Never clean sealed bearings using solvent or any other
cleaner. Carefully remove dirt, externally applied lubricants
and sediment with a rag or stiff bristle brush.

Chain Guard Assembly

Refer to Dwg. MHP1065.
1. Place the chain guard (5) in housing (1).
2. Install the chain guide (4) and loosely secure in place with
the chain guide capscrews (4A) and lockwashers (4B).
3. When hoist is completely assembled tighten capscrews.

Planet Gear Frame Assembly

Refer to Dwg. TPB705-2.
1. Press a new planet gear bearing (58) into each end of the
planet gears (57). Seat each bearing 1/64 in. (0.5 mm)
below the face of the gear.
2. Work a liberal amount of Ingersoll-Rand No. 11 grease
into the bore of the planet gear bearings. Ensure each of the
individual needles or rollers are thoroughly covered.
3. Stand the planet gear frame (54) on the table of an arbor
press with its short hub upward.
4. Wipe a thin film of Ingersoll-Rand No. 11 grease on both
ends of the planet gears (57) and on the planet gear thrust 13. Install the pinion gear (72) with a tooth of the pinion
races (60) and gear thrust bearings (59). Use enough entering each of “X” marked planet gear (57) spaces. The
lubricant to allow it to hold the parts in position. Place a pinion gear internal spline must be located towards the end
planet gear thrust race (60), gear thrust bearing (59) and a of the planet frame with the hub (brake end).
second gear thrust race (60) against each face of the planet 14. Ensure the retainer ring is installed on planet frame bearing
gear (57). (56). Place the planet frame spacer (55) on planet frame
5. Slide the planet gear/thrust races/thrust bearing assembly, bearing (56). Install the spacer on the side of the bearing
with the planet gear large diameter gear teeth located with the most clearance between the retainer ring and the
towards the short hub on the planet gear frame, into one end of the bearing. Press the bearing assembly into the
side of the planet gear frame. Press in a planet shaft (61) to planet frame (54), spacer (55) first, until spacer and retainer
secure the gear assembly in the gear frame. ring are flush with the frame.
6. Repeat steps 4 and 5 for the second and third planet gear 15. Lubricate and press seal (53) into end of ring gear (52).
assemblies. 16. Lubricate the gear splines and teeth on the planet gears and
7. Work a liberal amount of Ingersoll-Rand No. 11 grease ring gear (52) with Ingersoll-Rand No 11 grease. Align the
into the bore of the brake driver bearing (63A), making ‘•’ matchmarks on the planet gears (57) to similar ‘•’
certain that each individual needle or roller is covered. matchmarks on ring gear (52) and place the planet frame
Press the brake driver bearing (63A) into the bore of the assembly into the ring gear (52).
planet frame (54) hub. Seat bearing 3/16 in. (5 mm) below 17. To install in hoist, refer to ‘Hoist Assembly’ section.
the face of the hub into the bore of the planet frame (54)
hub. Motor Assembly
8. Install a new brake driver seal (63B) with the lip facing the Refer to Dwg. TPB703-3.
bearing (63A). 1. Grasp the motor shaft (38) vertically in copper-covered vise
9. Place the planet frame retainer (62), planet frame seal (65) jaws so that the short-splined end is upward.
and oil slinger (63) on planet frame (54) hub. Install planet 2. Press the front end plate bearing (47) into the front end
frame spacer (64) on hub. plate (46), and the rear end plate bearing (40) into the rear
10. Ensure the retainer ring is installed on planet frame bearing end plate (41). Apply grease to both bearings.
(63C). Press the bearing fully onto the planet frame (54) 3. Slide the front end plate and bearing, bearing side first,
hub. Ensure the retainer ring is located with the shortest down over the motor shaft until it seats against the motor
distance to the edge of the bearing towards the planet shaft shoulder.
frame. 4. Slide the rotor (42), counterbored end first, down over the
11. Position the planet gear frame (54) such that the pinion motor shaft until it contacts the front end plate.
gear (72A) or (72B) may be installed from the motor side 5. Moisten each vane (43) with SAE 10 or SAE 20 non-
of the planet frame assembly with the brake side accessible detergent oil, and place a vane in each slot in the rotor (42).
for correct timing mark alignment checks. 6. Set the cylinder (44) on the rotor, aligning the dowel hole
12. Refer to Dwg. MHP0569. Rotate the three planet gears in the cylinder with the dowel hole in the front end plate
until the “X”s on the ends are all located towards the center (46).
of the planet frame (54). The timing marks (‘•’) on the 7. Slide the rear end plate (41) and bearing (40) assembly,
planet gears (57) must locate on the centerline of the plate flat side first, onto the hub of the motor shaft until it
outside exposed gear splines. contacts the cylinder. Align the dowel hole in the rear end
plate with the dowel hole in the cylinder.
8. Install the motor rear retainer ring (39) in the annular
CAUTION groove on the end of the motor shaft (38).
9. Insert a 1/8 in. (3 mm) steel guide rod about 12 in. (305
• It is very important that the planet gears (57) and ring gear mm) long through the dowel holes in the end plates and
(52) are correctly aligned when the planet frame assembly is cylinder to maintain alignment of parts, and remove the
inserted into the ring gear. assembly from the vise.

26
10. To install in hoist, refer to ‘Hoist Assembly’ section.

Brake Assembly
Refer to Dwg. TPB704-3.
1. Lightly coat the piston seals (84) and (85) with ‘O’ ring
lubricant, and install them in their respective grooves on
the brake piston (83).
2. Taking care not to cut the seals, slide the piston into the
brake spring and piston housing (80).
3. Place the spring and piston housing on the workbench with
the three spring cavities facing upward.
4. Place a spring (81) in each cavity.
5. For New Style Pressure Plates (82): install the pressure
plate screw (82A) such that the screw head mates with the
counterbore in the pressure plate face. Place the pressure
plate (82) and screw over the springs so that the screw
enters the hole in the brake piston.
For Old Style Pressure Plates with and Integral Stud:
install the pressure plate, stud side first, over the springs so
that the stud enters the hole in the brake piston.

NOTICE
• For improved brake control it is recommended that the old (Dwg. MHP0488)
style pressure plate be replaced with the new style pressure
plate (82) and screw (82A). The old style pressure plate is not Valve Chest Assembly (New Style)
available as a replacement part. To replace order Brake Kit This procedure describes the assembly of valve chests used on
No. MLK-ABK1. hoists with the second letter of the Serial Number other than A
through G, or with second and third letters of the Serial Number
6. Carefully place the assembly in a vise and compress the other than HA, HB or HC, or hoist valve chests that have been
pressure plate against the brake springs and piston housing updated with Valve Chest Kit No. MLK-K545B. Replacement
until the screw protrudes through the piston. Thread the part numbers are listed in the Parts section. Refer to Dwg.
piston nut (82B) onto the screw at least two full thread TPA958-1.
lengths, but not enough to fully engage the nut. 1. If the valve chest cover pins (17) were removed, install
7. Slowly release the assembly from the vise. them in the bottom of the valve chest (6).
8. For New Style Pressure Plates: tighten the pressure plate 2. Apply a thin film of ‘O’ ring lubricant to the valve seals
screw (82A) and piston nut (82B) until a 0.006 to 0.012 in. (7A) and (8A) and install them on the valves (7) and (8).
(0.15 to 0.30 mm) gap exists between the pressure plate and
piston. Refer to Dwg. MHP0488. CAUTION
NOTICE • Do not substitute any other ‘O’ rings for the valve seals.

• When adjusted, the piston (83) assembly should free float 3. Install a valve spring (9) on the non-tapered end of each
between piston nut (82B) and pressure plate (82). Ensure valve and insert the valves, valve spring first, into the
piston moves freely between nut and pressure plate. openings at the bottom of the valve chest. Make certain the
valve marked UP is inserted into the opening marked UP
For Old Style Pressure Plates: torque the piston nut to 50 to VALVE and the valve marked DOWN is inserted in the
70 inch-lb (6 to 8 Nm). opening marked DOWN VALVE.

NOTICE NOTICE
• Ensure the piston extends completely through the spring • Some valves (7) and (8) were not marked UP and DOWN.
and piston housing and contacts the pressure plate. To determine correct placement, inspect these valves. A valve
with a shallow annular groove around the spring end hub is
9. Install the plate (87) in the recess of the spring and piston the DOWN valve. A valve without an annular groove around
housing (80) and secure using two plate screws (88). the spring end hub is the UP valve.
10. To complete brake installation in hoist, refer to ‘Hoist
Assembly’ section. 4. Apply a thin film of ‘O’ ring lubricant to the valve seat
shaft seals (10B). Install a seal in each valve seat (10).
5. Apply a thin film of ‘O’ ring lubricant to the valve seat
seals (10A) and install two seals on each valve seat.
6. Align the smaller diameter crosshole of the valve seat with
the threaded hole in the side of the valve chest for the valve
seat lock screw (11). With the hub end trailing, install the
valve seats in the valve chest.
7. Screw the valve seat lock screws into the valve chest. Make
certain they enter the valve seats. Torque the screws to 24
in lb (3 Nm).

27
8. Using retainer ring pliers and applying pressure to the hub
of the valve seat, install the valve seat retainers (12). Make NOTICE
certain the retainers seat in the grooves of the valve chest.
9. If the pistons (14) were separated from the piston shafts • Each valve sleeve has a notch in one end and a 7/16 inch (11
(15), apply a thin film of ‘O’ ring lubricant to each piston mm) diameter port in the wall of the sleeve. Inside the valve
shaft seal (15A) and install them in the grooves of the chest there is a 7/16 inch (11 mm) diameter cross-port that
piston shafts. connects the two valve chambers.
10. Slide the pistons onto the piston shafts with the small hub
of the piston toward the smallest diameter of the shaft. 2. Insert the valve sleeves, notched end first, into the valve
Align the crosshole in each piston with the crosshole in chest so that the 7/16 in. (11 mm) diameter port in each
each shaft and install the piston retaining pins (15B). sleeve is aligned with the cross-port in the valve chest, and
11. Apply a thin film of ‘O’ ring lubricant to the piston seals so that the notches in the sleeves face each other.
(14A) and install one on each piston. 3. Stand the valve chest up on the inlet port and insert a valve
12. Apply a thin coat of ‘O’ ring lubricant on the piston spring (327) and a valve (325) into each valve sleeve. Make
cylinder walls and insert the piston springs (13) into the certain each valve goes into its proper sleeve. These are
valve chest against the valve seat retainers. matched sets.
13. Install the assembled pistons and shafts in the valve chest. 4. Moisten each piston seal (331) with ‘O’ ring lubricant and
14. Apply a thin coat of ‘O’ ring lubricant to the valve chest install a seal in the groove on each piston (330).
cover seals (18A) and install them in the valve chest cover 5. Insert each piston rod (328 and 329), small end first,
(18). through its respective hole in the piston.
15. Align the valve chest cover gasket (16) with the valve chest 6. Install a piston nut (332) on each piston rod. Tighten the
cover pins and place the gasket against the valve chest. nut to a snug fit.
16. Align the valve chest cover with the valve chest cover pins 7. Moisten the valve chest cover seals (335) with ‘O’ ring
and piston shafts and place the cover against the valve lubricant, and install them in the valve chest cover (334).
chest. 8. Position the valve chest cover so that the bleed holes and
17. Install the six valve chest cover screws (22). Tighten screws adjustment screws (336) are facing you. Moisten the large
evenly and torque to 72 in lb (8 Nm). diameter of the piston rods with ‘O’ ring lubricant. Insert
18. Thread the adjustment screw locknuts (21) onto the bleed the longer piston rod (328) through the hole on the left
adjustment screws (19) and install the screws in the valve from the gasket side of the valve chest cover. Insert the
chest cover. shorter piston rod (329) through the hole on the right from
the gasket side.
9. Place a piston spring (333) in each valve cavity in the valve
NOTICE chest, and position the valve chest cover gasket (338) on
the bottom of the valve chest.
• Use these screws to adjust hoists with pendant control. 10. Taking care not to pinch the piston seals, install the
Refer to ‘Pendant Control Adjustments’ in the assembled valve chest cover to the bottom of the valve
“INSTALLATION” section. chest. Check to make sure the long stem piston rod (328) is
installed in “UP VALVE” side as marked on gasket face of
19. Manually work the piston shaft assemblies up and down valve chest. Tighten the valve chest cover screws (339)
when installed in the valve chest. The piston shafts must evenly a little at a time until all are tight.
shift smoothly with no indication of binding of parts.
Assembly of Hoist
Valve Chest Assembly (Old Style) 1. If removed, install new throttle shaft bearings (2) in the
This procedure describes the assembly of valve chests used on housing and apply a light coating of grease.
hoists with second letter of the Serial Number A through G or 2. Install the ‘O’ ring seal (51) in the housing.
with second and third letters of the Serial Number HA, HB, or 3. Install the chain guard (5) in the housing.
HC. Refer to Dwg. TPA883-3. 4. Install a new oil seal (53) in the output ring gear (52) with
the lip facing inward. Coat the lip with a film of oil or
grease.
NOTICE 5. Ensure the retainer ring is located on the shaft bearing (50).
Install the bearing on the ring gear (52) with the retainer
• Replacement parts for this valve chest are no longer ring end located towards the ring gear.
available. Order kit No. MLK-K545B (03835519) to replace 6. Lubricate the gear splines on the ring gear (52) shaft and
this style valve chest if it cannot be repaired. The following the chain wheel (51A) with Ingersoll-Rand No. 11 grease.
assembly instructions are provided for reference only. Install the chain wheel on ring gear shaft.
7. Install shaft bearing (49) onto the ring gear (52).
1. Moisten the valve sleeve seals (326) with ‘O’ ring lubricant 8. Install ring gear (52) assembly in housing.
and install them on the valve sleeves (325). 9. Install the chain guide (4), four chain guide capscrews (4A)
and lockwashers (4B).
CAUTION 10. Insert the motor retainer washer (48) in the housing. The
raised outer diameter should be toward the open/motor end
• When installing the valve and valve sleeve assemblies (325), of the housing.
make certain the valves do not get mixed. These are 11. Install the motor assembly in the housing by aligning the
assembled as matched sets. motor guide rod with the dowel hole in the bottom of the
housing and sliding the motor into the housing.
12. Remove the guide rod and replace it with a cylinder dowel
(45). Tapered end of dowel pin must enter first. Dowel
should be positioned approximately 1/8 in. (3 mm) below
the rear end plate (41) surface.

28
13. Place a housing gasket (3) on the motor end of the hoist 23. Stand the hoist upright on the brake end. Place the valve
and install the valve chest plate (28) and screws (30). chest gasket (25) on the valve chest plate, making certain
Check that motor shaft (38) turns freely by hand without that the small flapper is properly positioned in the recess
sticking or binding. between the two ports.
14. Note the matchmarks ‘•’ on the ring gear (52) and on the
three planet gears (57). The planet frame assembly must be
inserted into the hoist such that the pinion gear (72) WARNING
internal splines align with the motor shaft (38) splines.
Also, the matchmarks ‘•’ on the planet gears must align • If the valve chest gasket (25) is installed incorrectly, the
with the matchmarks ‘•’ on the ring gear. small flapper will not be in the recess between the two ports.
15. Place the gear case gasket (66) on the end of the housing The brake will not release and may cause damage to the
with the gasket hole aligned with the air port. hoist.
16. If removed, install the fixed ring gear (67) and ring gear
pins (68) in the gear case cover. 24. Center the two round rubber discs in corresponding
17. Install the gear case assembly with gasket on the hoist recesses in the valve chest plate.
aligning the ring gear roll pins and brake port. Install the 25. Place the assembled valve chest (6) on the valve chest
four bolts and lockwashers. gasket. Secure using the valve chest screws (26) and (27).
18. Install the brake driver (73), brake seal (75), brake seal 26. Install hoist load chain as described in the ‘Initial Chain
retainer (74), and brake driver retainer screw (76). Apply a Installation’ section.
small amount of silicone sealant to ‘O’ ring. The brake 27. Reposition hoist with brake end up. Place a brake plate (78)
driver retainer screw is a self-locking type screw that followed by a brake disc (79), brake plate (78), brake disc
should be replaced anytime the hoist is disassembled. (79), and two brake plates (78) over the brake driver (73),
Torque the screw to 50 in lb (5.65 Nm). aligning the notches in the brake plates with the bolt holes
19. Check that the brake driver turns freely by hand. If the in the gear case cover (69).
brake driver does not turn without restriction in both 28. Reposition hoist with brake end up. Install the assembled
directions the hoist must be inspected to determine the brake spring and piston housing (80), making sure the ‘O’
cause of sticking or binding before further assembly. ring (77) is installed at the air port. Install the four
20. If removed, assemble the upper suspension. On hook units, shoulder bolts (89) and lockwashers (90).
inspect the hook and hook latch as described in the 29. Place the limit actuator (33) on the square end of the
“INSPECTION” section. Assemble the latch to the hook. throttle shaft, and install the limit actuator retaining pin
Lubricate the thrust bearing (106). (34).
For HL1000K to HL3000K Hoists: 30. For new style hoists with second letter of the serial
Assemble the hook (102), thrust bearing (106), thrust number other than A through G or with second and third
washers (107), hook nut (104) and top yoke (101). Be letters of the serial number other than HA, HB or HC,
sure to install the roll pin (105) to lock the hook nut install the two pendant links (183) between the limit
on the hook. Mount the top yoke assembly or the lug actuator and the valve shafts.
mount kit to the hoist using lubricated capscrews and For old style hoists with pendant control with second
locking tabs under the capscrews. Torque the letter of the serial number A through G or with second and
capscrews to 75 - 125 ft lb (100 - 170 Nm). Bend the third letters of the serial number HA, HB or HC, install a
locking tabs over the capscrews flats to secure. pendant link (183) between the limit actuator and the long
For HL4500K and HL6000K Hoists: piston rod.
Lubricate the thrust bearing (131). Assemble the hook For old style hoists with pull chain control with second
(127), thrust bearing, hook nut (129) and upper letter of the serial number A through G or with second and
suspension housing (101). Be sure to install the hook third letters of the serial number HA, HB or HC, no
pin (130) to lock the hook nut on the hook. Mount the pendant links are required.
top yoke assembly or the lug mount kit to the hoist 31. Apply a thin film of ‘O’ ring lubricant to the swivel inlet
using lubricated capscrews and locking tabs under seals (24A). Install seals on inlet stud (24) grooves.
the capscrews. Torque the capscrews to 75 - 125 ft lb 32. Carefully push the inlet stud into the inlet body (23). Take
(100 - 170 Nm). Bend the locking tabs over the care to prevent cutting seals.
capscrew flats to secure. 33. Apply a thin film of ‘O’ ring lubricant to the swivel inlet
21. Place the throttle shaft spring (37) over the hub of the gasket (24B). Install the gasket on the inlet stud.
throttle lever (35) with the bent leg of the spring on the 34. Thread the inlet assembly into the top of the valve chest
outer side of the throttle lever. and tighten.
22. Hold the throttle lever in the housing recess beneath the
pocket wheel with the bent ends of the lever toward the Pendant Installation
valve chest end of the hoist and the legs of the throttle shaft Refer to Dwg. TPA0882-3.
spring engaging a rib on the bottom of the chain guide.
Insert the throttle shaft (32), round end first, through the CAUTION
valve chest plate, housing and throttle lever. Install a thrust
washer (36A) against the hub of the throttle lever. Install a • Disconnect the hoist from the air supply before performing
thrust washer (36A) against the throttle shaft spring. Install maintenance on this hoist.
the throttle lever retaining pin (36).
When installing a pendant assembly on HLK Hoists, a crimping
NOTICE tool (Part No. ML50K-930AT or a Nicopress® Tool with
Groove Size G) must be used to install the clamping sleeve
• On hoist models HL4500K and HL6000K the throttle lever (176) on the ends of the strain relief cable (175).
(35) may require adjustment to provide adequate clearance
with the upper suspension block. Minor modifications to the
throttle lever are acceptable to establish throttle lever
clearance.

29
The strain relief cable (175) must be long enough to allow the Chain Container
pendant hose to hang nearly straight yet short enough to absorb To Install Fabric Container
the pendant weight and forces. 1. Position the mounting bracket (301) between the bosses at
the bottom of the hoist in the area of the chain opening.
2. Insert two bracket bolts (302) from the inside of the chain
CAUTION container, through the mounting bracket and bosses. The
bracket bolt heads should contact the mounting bracket.
• Ensure the strain relief cable supports the pendant. Do not 3. Place a washer (304) and bracket nut (303) on each bracket
allow the pendant hoses support the weight of the pendant. bolt.
Hose failure can cause injury and loss of hoist control.

NOTICE NOTICE
• If the container is to be allowed to swing outward, tighten
• When the control hoses are cut to length, the hose at the the bracket nuts (303) to within one turn of being fully tight.
back of the pendant (air in) should extend 6 in. (150 mm) This will allow the container to swing away from a load.
beyond the top clamping thimble.
4. Because of space limitations, it may be necessary to depress
Depending upon which valve chest is used on the hoist, the the throttle lever (35) to install the bracket bolts (302) on
length of the two hoses at the front of the handle will vary. hoists equipped with a hand chain throttle. Hoists equipped
1. On the new style MLK-A545A valve chest, the hoses with a pendant throttle may require removal of the pendant
should extend 2 in (51 mm) beyond the top clamping links (183) to install the bracket bolts. Reinstall the pendant
thimble (177). Refer to Dwg. TPB767. links after the mounting bracket is attached to the hoist.
5. Fasten the support bracket (305) to the outside of the chain
container with the bracket nut and washer located to the
outside of the chain container.
6. Fasten the chain container to the mounting bracket in the
same manner.
7. Carefully disassemble the chain anchor (91) and attach one
end of the support chain (306) onto the chain anchor with
the load chain (92).

CAUTION
• Make certain the load chain does not become twisted when
attaching the support chain to the chain anchor.

8. Fasten the free end of the support chain to the support

bracket with the support bracket bolt (307), support bracket
washer (309) and the support bracket nut (308).

2. On the old style MLK-A545 valve chest, the hoses should

extend 4 in (100 mm) beyond the top clamping thimble
NOTICE
(177). Refer to Dwg. TPB766.
• Adjust the support chain at the support bracket to prevent
the load chain from rubbing against the container when
operating the hoist.

To Install Metal Chain Container HLK-K750

Refer to Dwg. MHP1029
The following instructions are for adding the HLK-K750 metal
chain container kit to a standard hoist. If installing an existing
chain container, ignore Step 2 and the first part of Step 3
(connecting link) describing replacement of the limit actuator.
1. Run bottom block to lowest point to provide access to the
installation area on the hoist. Disconnect hoist from air
supply.

WARNING
• Disconnect the hoist from the air supply before installing
chain container.
3. Install one hose tie (218) above the pendant handle (160) 2. If installing the container for the first time (kit installation),
and one hose tie below the clamping thimble (177). Install remove links (183) from limit actuator (33). Drive out limit
the remaining hose ties every 2-1/2 feet (0.76 m) between actuator retaining pin (34). Remove limit actuator from
the hose ties at the handle and thimble. throttle shaft (32). Replace with limit actuator (315).
4. Install the warning tag such that the tag can be read by the Reinstall limit actuator retaining pin and links.
operator from the lever side of the pendant handle.

30
3. Disconnect the last link of load chain from hoist by
separating connecting link (91). Slide stop ring NOTICE
approximately 16 links (minimum of 5.38 in (136 mm))
from dead end of load chain. Refer to Dwg. MHP1226. • Operate the hoist to naturally pile chain into the chain
Secure in place by installing pin (320) and setscrew (321). container. Piling the chain carelessly into the container by
hand may lead to kinking or twisting that may cause chain to
jam the hoist.

7. Tighten all screws. Provide supply air to hoist, and run

chain into container.

Load Test
Prior to initial use, all new, extensively repaired, or altered
hoists shall be load tested by or under the direction of personnel
instructed in safety, maintenance and operation of this hoist. A
written report must be maintained on record confirming the
rating of the hoist.
1. Operate the hoist fully in both directions without a load.
Hoist must operate smoothly, without evidence of binding.
Response to operating controls must be quick and accurate.
2. Place a 10% load on hoist and operate hoist fully in both
(Dwg. MHP1226) directions. Hoist must operate smoothly, without evidence
of binding. Response to operating controls must be quick
4. Ensure chain is straight. Place bracket (317) on last link of and accurate.
load chain such that the bracket angle will be downward 3. Dynamically load test hoist to 100% of its rated capacity.
when attached to the chain container (318). Hoist must operate smoothly, without evidence of binding.
5. Position the chain container (318) between the bosses at the Response to operating controls must be quick and accurate.
bottom of the hoist in the area of the chain opening. Insert
two bracket bolts (324) from the inside of the chain
container, through the mounting bracket and bosses. The NOTICE
bracket bolt heads should contact the mounting bracket.
Install lockwashers (325) and nuts (326) loosely on screws. • Testing to more than 100% may be necessary to comply
6. Attach bracket (317) to chain container with the bracket with standards and regulations set forth in areas outside of
angle downward. Secure to chain container using screws the USA.
(322), lockwashers (316) and nuts (303).

31
 HOIST ASSEMBLY DRAWING AND PARTS LIST TABLE OF CONTENTS

Hoist Parts Section Guide (Dwg. TPA884-3) ................................................................................................................................................ 33

Hoist Housing Assembly Parts Drawing (Dwg. MHP1065) ........................................................................................................................ 34
Hoist Housing Assembly Parts List ................................................................................................................................................................. 35
Hoist Valve Chest Assembly Parts Drawing (Dwg. TPA958-1) ................................................................................................................... 36
Hoist Valve Chest Assembly Parts List ........................................................................................................................................................... 37
Hoist Gearing Assembly Parts Drawing (Dwg. TPB705-2) ......................................................................................................................... 38
Hoist Gearing Assembly Parts List ................................................................................................................................................................. 39
Hoist Brake Assembly Parts Drawing (Dwg. TPB704-3) ............................................................................................................................. 40
Hoist Brake Assembly Parts List ..................................................................................................................................................................... 41
Motor Assembly Parts Drawing (Dwg. TPB703-3) and Parts List .............................................................................................................. 42
Top Lug Assembly Drawing (Dwg. TPC449-3) and Parts List .................................................................................................................... 43
HL1000K, HL1000KR and HL1500K Hook Assembly Parts Drawing (Dwg. MHP1105) ........................................................................ 44
HL1000K, HL1000KR and HL1500K Hook Assembly and Parts List ......................................................................................................... 45
HL2000K and HL3000K Hook Assembly Parts Drawing (Dwg. MHP1106) ............................................................................................. 46
HL2000K and HL3000K Hook Assembly Parts List ..................................................................................................................................... 47
HL4500K Hook Assembly Parts Drawing (Dwg. TPA1041) ....................................................................................................................... 48
HL4500K Hook Assembly Parts List .............................................................................................................................................................. 49
HL6000K Hook Assembly Parts Drawing (Dwg. TPA1040) ....................................................................................................................... 50
HL6000K Hook Assembly Parts List .............................................................................................................................................................. 51
Pendant Assembly Parts Drawing (Dwg. TPA0882-3) ................................................................................................................................. 52
Pendant Assembly Parts List ........................................................................................................................................................................... 53
Fabric Chain Container Assembly Parts Drawing (Dwg. TPC451-3) .......................................................................................................... 54
Fabric Chain Container Assembly Parts List .................................................................................................................................................. 55
Metal Chain Container Assembly Parts Drawing (Dwg. MHP1029)........................................................................................................... 56
Metal Chain Container Assembly Parts List ................................................................................................................................................... 57
Trolley Assembly Information ......................................................................................................................................................................... 58
Repair and Conversion Kits ............................................................................................................................................................................. 59
Accessories ....................................................................................................................................................................................................... 60
Old Style Valve Chest Assembly Drawing (Dwg. TPA883-3) and Parts List .............................................................................................. 61

32
HOIST PARTS SECTION GUIDE

33
HOIST HOUSING ASSEMBLY PARTS DRAWING

34
 HOIST HOUSING ASSEMBLY PARTS LIST

ITEM DESCRIPTION QUANTITY PART

NO. OF PART TOTAL NUMBER
--- Housing Assembly 1 HLK-A300
1 Housing 1 Not sold separately *
• 2 Throttle Shaft Bearing 2 H54U-511
2A Vent Plug 1 CE210-120
2B Level and Drain Plug 2 R0H-377
• 3 Housing Gasket 1 ML50K-445
4 Chain Guide 1 HLK-741
4A Chain Guide Screw 4 G57T-634
4B Lockwasher 1 Pack of 10 8U-58-10
5 Chain Guard 1 HLK-6
• 29 Throttle Lever Bearing 1 R38M-603
32 Throttle Shaft 1 MHLK-255
Limit Actuator (Old Style Hoist) ** 1 MLK-251
33
Limit Actuator (New Style Hoist) ** 1 MLK-251A
34 Limit Actuator Retaining Pin 1 WF171-15
35 Throttle Lever 1 HLK-556
36 Throttle Lever Retaining Pin 1 WF171-15
36A Throttle Lever Thrust Washer 2 MR-458
37 Throttle Shaft Spring 1 MR-412
66 Gear Case Gasket 1 HLK-31
91 Connecting Link 1 HRA30A-646
Standard Pull Chain CA110-B240
93 Specify Length x 2
HL1000KR Spark Resistant Pull Chain D02-1413
--- Pull Chain Conversion Kit (without Pull Chain) *** 1 MLK-K415
94 ‘S’ Hook 4 D02-421
95 Throttle Handle 2 MR-415
96 Plug, Pipe (shown on Dwg. TPA958-1) 1 R0H-377
97 Plug, Vent (shown on Dwg. TPA958-1) 2 P250-546
99 Bar, Handle (optional) 1 MR-409
151 Warning Label 1 04306445
152 Serial Number Label Plate 1 MLK-301S-R
155 Fasteners, Label Plate 4 R4K-302
156 Model Number Label Plate 1 MLK-301M-R

• Recommended Spare
* Housing (1) not sold separately; purchase housing assembly (HLK-A300).
** New Style Hoist refererences apply to hoists with second letter of the serial number other than A through G or with
second and third letters other than HA, HB, or HC.
Old Style Hoist refererences apply to hoists with second letter of the serial number A through G or with second and third
letters HA, HB, or HC.
*** Pull Chain Conversion Kit replaces item 33 (Limit Actuator) on Dwg. MHP1065, items 181 (Fitting, Elbow) and 182
(Fitting Nipple) on Dwg. TPA958-1, and attached pendant (including control hoses).

35
HOIST VALVE CHEST ASSEMBLY PARTS DRAWING

36
 HOIST VALVE CHEST ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NUMBER NO. OF PART TOTAL NUMBER
3 Housing Gasket 1 ML50K-445 22 Valve Chest Cover Screw 6 MLK-240
--- Valve Chest Assembly 1 MLK-A545B --- Swivel Inlet Assembly 1 MLK-A4
6 Valve Chest 1 MLK-545A 23 Inlet Body 1 MLK-166
7 Up Valve Assembly 1 MLK-K102U 24 Inlet Stud 1 MLK-B4
• 7A Up Valve Seal 1 MLK-211 • 24A Swivel Inlet Seal 2 R4-210
8 Down Valve Assembly 1 MLK-K1102D • 24B Swivel Inlet Gasket 1 R18LF-21
• 8A Down Valve Seal 1 MLK-211 24C Inlet Strainer 1 MLK-82
9 Valve Spring 2 MLK-942A • 25 Valve Chest Gasket 1 Set MLK-928-80
10 Valve Seat Assembly 2 MLK-K615 26 Valve Chest Screw 1 518-104
• 10A Valve Seat Seal 2 C321-606 27 Valve Chest Screw 2 R0H-354-4
• 10B Valve Seat Shaft Seal 1 R000BR-210 28 Valve Chest Plate 1 HLK-549
11 Valve Seat Lock Screw 2 AF160-305 • 29 Throttle Lever Bearing 1 R38M-603
• 12 Valve Seat Retainer 2 MLK-218 30 Valve Chest Plate Screw 5 5080-638-4
13 Piston Spring 2 MLK-250A 31 Muffler 2 MLK-175
14 Piston Assembly 2 MLK-K246A 32 Throttle Shaft 1 MHLK-255
• 14A Piston Seal 1 HLK-103 Limit Actuator
MLK-251
15 Piston Shaft Assembly 2 MLK-K655A (Old Style Hoists) *
33 1
• 15A Piston Shaft Seal 1 R0BR1C-283 Limit Actuator
MLK-251A
• 15B Piston Retaining Pin 1 510-669A (New Style Hoist) *
• 15C ‘O’ Ring 1 R2F-167 34 Limit Actuator Retaining Pin 1 WF171-15
16 Gasket 1 MLK-117A 96 Plug, Pipe (Pull Chain) ** 1 R0H-377
17 Pin 2 MLK-241 97 Plug, Vent (Pull Chain) ** 2 P250-546
18 Cover Assembly 1 MLK-A238A 153 Ingersoll-Rand Logo 1 HRA20A-201
• 18A Valve Chest Cover Seal 2 R000BR-210 181 Fitting, Elbow (Pendant) ** 1 UWD-161
19 Bleed Adjustment Screw 2 MLK-370 182 Fitting, Nipple (Pendant) ** 2 MLK-165
20 Muffler 2 MLK-236 183 Link 2 MLK-224
21 Adjustment Screw Locknut 2 Q1-121

Repair and Conversion Kits

Valve Chest Repair Kit Includes items 7A, 8A, 9, 10A, 10B, 12, 13, 14A, 15A, 15B, 16,
--- 1 MLK-VCK1
For New Style Hoist* only. 17, 18A, 24A, 24B, 24C, 25 and 183.
Overhaul Gasket Kit for all Includes items 3, 7A, 8A, 10A, 10B, 12, 14A, 15A, 15B, 18A
HLK Hoists (numbers in (335), 24A, 24B, 25, 34, 36, 39, ‘O’ ring for 49, 51, 53, 63B, 64,
--- 1 HLK-K445
paranthesis are for Old Style 65, 66, 75, 76, 77, 84, 85, 105, 109, 114, 119, 130, 138, 144, 162,
Hoist valve chest parts) 164, 180, 183 and (331).

• Recommended Spare
* New Style Hoist refererences apply to hoists with second letter of the serial number other than A through G or with second
and third letters other than HA, HB, or HC.
Old Style Hoist refererences apply to hoists with second letter of the serial number A through G or with second and third
letters HA, HB, or HC.
** Pull Chain Conversion Kit (MLK-K415) provides items 94 through 98 to convert hoist to pull chain operation. Items 33, 181,
182 and attached pendant (including control hoses) are replaced by this conversion. Order Pull Chain (93) separately. Refer to
Dwg. MHP1065 parts list for detailed information.
Pendant Conversion Kit (MLK-AL269C) includes all components necessary to convert a pull chain throttle hoist to pendant
control operation used on MLK, MLKR, HLK and HLKR hoists. Items 93 through 98 are replaced by this conversion. Length
of pendant hose must be specified when ordering. Pendant length is normally 5 ft (1.5 m) shorter than lift. Refer to Dwg
TPA0882-3 for additional pendant information.

37
HOIST GEARING ASSEMBLY PARTS DRAWING

38
 HOIST GEARING ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NO. NO. OF PART TOTAL NO.
38 Motor Shaft 1 HLK-316 63A Brake Driver Bearing 1 182A83-606
49 Housing Bearing 1 HRA20A-987 63B Brake Driver Seal 1 HLK-137
50 Ring Gear Bearing 1 HLK-97 63C Planet Frame Bearing 1 HLK-97
• 51 ‘O’ Ring 2 HLK-21 64 Planet Frame Spacer 1 R2C-103
51A Chain Wheel (Powered) 1 HLK-740 65 Planet Frame Seal 1 HLK-103
52 Ring Gear 1 HLK-798 • 66 Gear Case Gasket 1 HLK-31
• 53 Seal 1 HLK-457 67 Fixed Ring Gear 1 HLK-406
--- Planet Frame Assembly 1 Contact factory 68 Ring Gear Pin 4 HLK-20
54 Planet Frame 1 HLK-8 69 Gear Case Cover 1 HLK-353
55 Planet Frame Spacer 1 HLK-645 70 Gear Case Screw 4 21-702
56 Planet Frame Bearing 1 HLK-96 71 Lockwasher 4 UW50A30-58
57 Planet Gear Assembly 3 HLK-A10 Pinion Gear
58 Gear Bearing 6 182A83-606 For HL1500K,
59 Gear Thrust Bearing 6 R02W-696
• 72A
HL3000K, HL4500K
HLK-319-12

60 Gear Thrust Race 12 CE210-603 and HL6000K

1
61 Planet Shaft 3 HLK-191 Pinion Gear
62 Planet Frame Retainer 1 HLK-39 For HL1000K,
• 72B HLK-319-15
• 63 Oil Slinger 1 HLK-974 HL1000KR and
HL2000K

• Recommended Spare

39
HOIST BRAKE ASSEMBLY PARTS DRAWING

40
 HOIST BRAKE ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NO. NO. OF PART TOTAL NO.
38 Motor Shaft 1 HLK-316 81 Spring 3 MLK-832
• 51 ‘O’ Ring 2 HLK-21 82 Pressure Plate 1 ML50K-K338A
63B Brake Driver Seal 1 HLK-137 82A Pressure Plate Screw 1 ML50K-805A
• 66 Gear Case Gasket 1 HLK-31 82B Piston Nut 1 ML50K-394
67 Fixed Ring Gear 1 HLK-406 83 Piston 1 ML50K-A809
68 Ring Gear Pin 4 HLK-20 • 84 Piston Large Seal 1 R2C-103
69 Gear Case Cover 1 HLK-353 • 85 Piston Small Seal 1 MLK-210
70 Gear Case Screw 4 21-702 87 Plate 1 ML50K-981
71 Lockwasher 4 UW50A30-58 88 Plate Screw 2 CE110-354
• 73 Brake Driver 1 ML50K-842 89 Shoulder Bolt 4 HLK-7
74 Brake Seal Retainer 1 HLK-639 90 Lockwasher (Qty. 10/pack) 1 Pack D02-321-10
• 75 Brake Seal 1 R18L-14 Capacity Labels See Below
• 76 Retainer Screw 1 HLK-640 HL1000K and HL1000KR
ML1000K-99
• 77 ‘O’ Ring (Air Port) 1 PS3-67 (1 ton)
78 Brake Plate 4 ML50K-834A HL1500K (1-1/2 ton) HL1500K-99
154 1
• 79 Brake Disc 2 ML50K-855A HL2000K (2 ton) HL2000K-99
Brake Spring and Piston HL3000K (3 ton) HL3000K-99
--- 1 MLK-A395A
Housing Assembly HL4500K (4-1/2 ton) HL4500K-99
80 Spring and Piston Housing 1 ML50K-395A HL6000K (6 ton) HL6000K-99

Repair and Conversion Kits

- - - Brake Repair Kit 1 MLK-ABK1 Includes items 79, 81, 84 and 85.
Includes all components for a manual release brake and/or 200%
--- Manual Brake Release Kit 1 MLK-K390
brake capability.

• Recommended Spare

41
 MOTOR ASSEMBLY DRAWING AND PARTS LIST

ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NO. NO. OF PART TOTAL NO.
--- Motor Assembly 1 HLK-A53 • 43 Vane Packet set of 7 MR-42-7
38 Motor Shaft 1 HLK-316 44 Cylinder 1 MR-3A
Motor Shaft Rear Retainer 45 Cylinder Dowel 1 R3H-434
39 1 MLK-120
Ring 46 Front End Plate 1 MR-11
• 40 Rear End Plate Bearing 1 R2-24 • 47 Front End Plate Bearing 1 TB-394
41 Rear End Plate 1 MR-12 48 Motor Retainer Washer 1 MR-207
42 Rotor 1 MR-53

• Recommended Spare

42
 TOP LUG ASSEMBLY DRAWING AND PARTS LIST

ITEM DESCRIPTION QTY. PART NO.

NO. OF PART TOTAL HL1000K/HL1000KR HL1500K HL2000K/HL3000K
--- Top Lug Kit 1 HLK-K444A HL3000K-K444A
• 109 Locking Tab 2 HLK-322
134 Lug Block 1 HLK-444A
135 Lug Mounting Block 1 HLK-425
136 Bolt (1.5 inch long) 2 215-36
137 Bolt (1.25 inch long) 2 215-13
• 138 Locking Tab 1 HLK-323
139 Bolt (2.25 inch long) 2 215-22
142 Chain Anchor 1 --- HLK-373
143 Pin 2 --- HLK-962
• 144 Cotter Pin 2 --- D02-330

• Recommended Spare
Note 1: Torque bolts (items 136, 137 and 139) to between 75 and 125 ft lbs (100 and 170 Nm).
Note 2: The head of pin (item 143) must be located on the motor side of the chain anchor (item 142).

43
HL1000K, HL1000KR AND HL1500K HOOK ASSEMBLY PARTS DRAWING

44
 HL1000K, HL1000KR AND HL1500K HOOK ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART NO.

NO. OF PART TOTAL HL1000K and HL1500K HL1000KR
Load Chain:
Load Chain (Zinc Plated) Specify H745Z ---
92 Length
Load Chain (Stainless Steel) in feet --- H745S

Top Hook: Standard Bullard Burnham Bronze

--- Top Hook Assembly 1 HLK-K590 HLK-KBB590 HLK-KR590A
101 Yoke 1 HL1500K-590
108 Capscrew 4 215-36
• 109 Locking Tab 2 HLK-322
--- Hook and Nut Assembly 1 HLK-AS377 HLK-ABB377 ---
104 Hook Nut 1 HLK-305
102 Hook and Latch 1 HLK-S377 HLK-BB377 HL1500K-SR377
• 117 Latch Kit 1 D01-S4055 --- D01-S4055
• 105 Pin 1 C6H20A-826
• 106 Bearing 1 HRA60A-379
• 107 Bearing Washer 2 HLK-465

Bottom Hook: Standard Bullard Burnham Bronze

--- Bottom Hook Assembly 1 HLK-K463 HLK-KBB463 HLK-KR463A
115 Hook Block 2 HLK-463 HLK-R463
122 Capscrew (Qty. 4 per pack) 1 pack 834-638-4
122A Nut 2 D02-428
Lockwasher (Qty. 10 per
122B 1 pack 34U-58-10
pack)
--- Hook and Nut Assembly 1 HLK-AS377 HLK-ABB377 ---
118 Hook Nut 1 HLK-305
116 Hook and Latch 1 HLK-S377 HLK-BB377 HL1500K-SR377
• 117 Latch Kit 1 D01-S4055 --- D01-S4055
• 119 Pin 1 C6H20A-826
• 120 Bearing 1 HRA60A-379
• 121 Bearing Washer 2 HLK-465

• Recomended Spare

45
HL2000K AND HL3000K HOOK ASSEMBLY PARTS DRAWING

46
 HL2000K AND HL3000K HOOK ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART NO.

NO. OF PART TOTAL HL2000K HL3000K
Load Chain:
Specify
92 Load Chain (Zinc Plated) Length H745Z
in feet
Bullard Bullard
Top Hook: Standard Bronze Standard Bronze
Burnham Burnham
--- Top Hook Assembly 1 HL2000K-K590 --- HL3000K-K590 ---
101 Yoke 1 HL3000K-590
• 109 Locking Tab 2 HLK-322
110 Capscrew (1.5 in long) 2 215-36
111 Capscrew (2.75 in long) 2 HU40-775
112 Chain Anchor 1 HLK-373
113 Pin 2 HLK-962
* 114 Cotter Pin 2 D02-330
Hook and Nut
--- 1 HL2000K-AS377 HL2000K-ABB377 HL2000K-ASR377 HL3000K-AS377 HL3000K-ABB377 HL3000K-ASR377
Assembly
102 Hook and Latch 1 HL2000K-S377 HL2000K-BB377 HL2000K-SR377 HL3000K-S377 HL3000K-BB377 HL3000K-SR377

• 117 Latch Kit 1 D02-S4055 --- D04-S4055 --- D02-S4055

104 Hook Nut 1 HL2000K-305A HL3000K-305
104A Hook Nut Spacer ** 1 HL2000K-306 ---
• 105 Pin 1 D660A-376
• 106 Bearing 1 CE110-295
• 107 Bearing Washer 2 HL3000K-465
Bullard Bullard
Bottom Hook: Standard Bronze Standard Bronze
Burnham Burnham
--- Bottom Hook Assembly 1 HL2000K-K378 --- HL3000K-K378 ---
125 Hook Block 2 HLK-378
126 Capscrew 4 AHC68-22
126A Lockwasher 4 UW50A30-58
128 Plate 2 ML50K-981
129 Screw 4 AF160-305
130 Idler Chain Wheel 1 HLK-380
• 131 Bearing 2 BU-359
132 Load Label 2 HL2000K-99 HL3000K-99
Hook and Nut
--- 1 HL2000K-AS377 HL2000K-ABB377 HL2000K-ASR377 HL3000K-AS377 HL3000K-ABB377 HL3000K-ASR377
Assembly
116 Hook and Latch 1 HL2000K-S377 HL2000K-BB377 HL2000K-SR377 HL3000K-S377 HL3000K-BB377 HL3000K-SR377

• 117 Latch Kit 1 D02-S4055 --- D01-S4055 --- D04-S4055

118 Hook Nut 1 HL2000K-305A HL3000K-305
118A Hook Nut Spacer ** 1 HL2000K-306 ---
• 119 Pin 1 D660A-376
• 120 Bearing 1 CE110-295
• 121 Bearing Washer 2 HL3000K-465

• Recomended Spare ** Not shown on drawing.

47
HL4500K HOOK ASSEMBLY PARTS DRAWING

48
 HL4500K HOOK ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART NO.

NO. OF PART TOTAL Standard Bronze Bullard Burnham
101 Upper Suspension Housing 1 HL4500K-590
102 Capscrew 2 KX-36
103 Capscrew 2 D01-339
104 Tab Washer 2 HLK-322
106 Idler Wheel Assembly 2 HL6000K-A380
107 Idler Wheel Bearing 1 48NB-765
108 Idler Wheel Seal 2 C6H20A28-754
109 Idler Wheel Thrust Washer 2 each Idler Wheel HL6000K-974
110 Idler Wheel Shaft 1 each Idler Wheel HL6000K-382
111 Wheel Shaft Grease Fitting 1 each Shaft R1-188
112 Wheel Shaft Lockplate 1 each Shaft MR20-383
113 Capscrew 2 each Lockplate JC3350-103
114 Lockwasher 2 each Lockplate L01-67-10
115 Idler Wheel Cover 1 each Idler Wheel HLK-441
116 Idler Wheel Chain Guard 1 each Idler Wheel HLK-445
117 Capscrew 4 Upper Idler Wheel R2N-103
117A Capscrew 4 Lower Idler Wheel R3-7-4
118 Lockwasher 4 Lower Idler Wheel L01-67-10
119 Chain Anchor Pin 1 HL6000K-962
120 Anchor Pin Lockplate 1 HL6000K-462
121 Capscrew 2 JC3350-103
122 Lockwasher 2 L01-67-10
123 Lower Hook Block 1 HL4500K-378
Top and Bottom Hook:
1-Lug Mount
--- Top and Bottom Hook Assembly HL4500K-AS377 HL4500K-ASR377 HL4500K-ABB377
2-Hook Mount
127 Hook 1 HL4500K-S377 HL4500K-SR377 HL4500K-BB377
• 128 Latch Kit 1 D04-S4055 D10-S4055 ---
129 Hook Nut 1 HL4500K-305
130 Hook Pin 1 D660A-376
131 Hook Thrust Bearing 1 HL4500K-379

• Recommended Spare

49
HL6000K HOOK ASSEMBLY PARTS DRAWING

50
 HL6000K HOOK ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART NO.

NO. OF PART TOTAL Standard Bronze Bullard Burnham
101 Upper Suspension Housing 1 HL6000K-590
102 Capscrew 2 KX-36
103 Capscrew 2 D01-339
104 Tab Washer 2 HLK-322
105 Limit Stop Tube 1 HL6000K-259
106 Idler Wheel Assembly 3 HL6000K-A380
107 Idler Wheel Bearing 1 each Idler Wheel 48NB-765
108 Idler Wheel Seal 2 each Idler Wheel C6H20A28-754
109 Idler Wheel Thrust Washer 2 each Idler Wheel HL6000K-974
110 Idler Wheel Shaft 1 each Idler Wheel HL6000K-382
111 Wheel Shaft Grease Fitting 1 each Shaft R1-188
112 Wheel Shaft Lockplate 1 each Shaft MR20-383
113 Capscrew 2 each Lockplate JC3350-103
114 Lockwasher 2 each Lockplate L01-67-10
115 Idler Wheel Cover (Upper Hook) HL6000K-441
1 each Idler Wheel
115A Idler Wheel Cover (Bottom Hook) HLK-441
Idler Wheel Chain Guard (Upper
116 HL6000K-445
Hook)
1 each Idler Wheel
Idler Wheel Chain Guard (Bottom
116A HLK-445
Hook)
117 Capscrew 4 Upper Idler Wheel R2N-103
117A Capscrew 8 Lower Idler Wheel R3-7-4
118 Lockwasher 8 Lower Idler Wheel L01-67-10
119 Chain Anchor Pin 1 HL6000K-962
120 Anchor Pin Lockplate 1 HL6000K-462
121 Capscrew 2 JC3350-103
122 Lockwasher 2 L01-67-10
123 Lower Hook Block 2 HL6000K-378
124 Pin 2 JC3350-74
125 Capscrew 2 HLK-638
126 Lockwasher 2 HRA20A-322
Top and Bottom Hook:
1-Lug Mount
--- Top and Bottom Hook Assembly HL6000K-AS377 HL6000K-ASR377 HL6000K-ABB377
2-Hook Mount
127 Hook 1 HL6000K-S377 Order complete hook assembly
• 128 Latch Kit 1 D10-S4055 HL6000K-SR4055 ---
129 Hook Nut 1 D10-305B
130 Hook Pin 1 D6100A-376
131 Hook Thrust Bearing 1 D10-379A

• Recommended Spare

51
PENDANT ASSEMBLY PARTS DRAWING

52
 PENDANT ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY.

PART NO. PART NO.
NO. OF PART TOTAL NO. OF PART TOTAL
--- Pendant Kit* 1 MLK-K269C Strain Relief Cable
175 1 BWR3A
160 Pendant Assembly ** 1 MLK-A269C (specify length)
161 Pendant Throttle Valve 2 MLK-K264B Clamping Sleeve
176 2 MLK-521
• 162 Valve Seal 2 R000BR1C-283 (see note 3)
163 Valve Cap 2 MLK-K266A 177 Clamping Thimble 2 MLK-602
• 164 Valve Spring 2 MLK-51A • 180 Valve Cap Gasket 2 MLK-504
165 Throttle Lever 2 MLK-273 182 Fitting, Hose 5 MLK-165
166 Throttle Lever Pin 1 DLC-120A Quick Exhaust Valve
224 *** 20417
167 Lockwasher 2 D02-138 Assembly
168 Strain Relief Support 1 MLK-450
169 Lockwasher 1 pack H54U-352-10
170 Handle Screw 4 HRE20A-68 Parts Not Illustrated
171 Hose (specify length) 3 50923 179 Warning Tag 1 71059612
172 Plug 1 502-95 Hose Tie (3 for standard hose;
218 HRE20A-283
173 Barbed Swivel Fitting 6 51029 2 additional each 5 ft hose)
Strain Relief Assembly Fitting, Elbow
--- 1 MLK-LWR3A --- 1 UWD-161
(specify length) (supply air inlet)

Additional Pendants and Components:

Includes all components necessary to install complete pendant
Single Motor Pendant with Hose Kit MLK-AL269C assembly. Specify hose length in feet (normally 4 ft (1.2 m) shorter
than lift).
Two Motor Pendant 1 HRA-A122C Two motor pendant without hose.
Three Motor Pendant HRA-A132C Three motor pendant without hose.
Two Motor Pendant (with hose) MLK-AL122C Two motor pendant with hose; specify hose length in feet.
Three Motor Pendant (with hose) MLK-AL132C Three motor pendant with hose; specify hose length in feet.

• Recommended Spare
*
Pendant Kit including items 161 through 173 and 176 through 182.

**
Includes 161 through 172, 180 and 182.

*** Quantity of 2 required when hose length exceeds 20 ft (6 m); quantity of 4 required when hose length exceeds 50 ft
(16 m).
Notes: 1. Refer to Form P6778 for additional information on pendant throttle handle assemblies.
2. On Old Style valve chests (hoists with the second letter of their serial number A through G or with second and third
letters HA, HB, or HC) order (2) MLK-161 adapters. MLK-1671 is a 1/8 NPT to 7/16-20 elbow.
3. A crimping tool (Nicropress® Tool with groove size G) is required to install the clamping sleeves (176).

53
FABRIC CHAIN CONTAINER ASSEMBLY PARTS DRAWING

54
 FABRIC CHAIN CONTAINER ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NO.
Fabric Chain Container Kit (single fall hoist capacity 20 ft [6 m] or on double fall
HLK-K749-20
hoist 10 ft [3 m])
--- 1
Fabric Chain Container Kit (single fall hoist capacity 40 ft [12 m] or on double fall
HLK-K749-40
hoist 20 ft [6 m])
Fabric Chain Container (20 ft [6 m] of chain capacity) HLK-749-20
300 1
Fabric Chain Container (40 ft [12 m] of chain capacity) HLK-749-40
301 Mounting Bracket 1 HLK-748
302 Bracket Bolt 6 SP9-11B
303 Bracket Nut 6 551AMP61-428
304 Washer 6 B8-259
305 Support Bracket 1 HLK-747
306 Support Chain 1 HLK-240-7
307 Support Bracket Bolt 1 R3H-68A
308 Support Bracket Nut 1 HLK-751
309 Support Bracket Washer 1 R3-94

55
METAL CHAIN CONTAINER ASSEMBLY PARTS DRAWING

56
 METAL CHAIN CONTAINER ASSEMBLY PARTS LIST

ITEM DESCRIPTION QTY. PART

NO. OF PART TOTAL NUMBER
Metal Chain Container Kit (single fall hoist capacity 20 ft [6 m] or on double fall
HLK-K750-20
hoist 10 ft [3 m])
Metal Chain Container Kit (single fall hoist capacity 40 ft [12 m] or on double fall
--- 1 HLK-K750-40
hoist 20 ft [6 m])
Metal Chain Container Kit (single fall hoist capacity 80 ft [24 m] or on double fall
HLK-K750-80
hoist 40 ft [12 m])
34 Pin 1 WF171-15
183 Link 2 MLK-224
303 Nut 2 551AMP61-428
315 Limit Actuator (required for large capacity HLK-K750-80 container kit) * 1 MLK-251PC
316 Lockwasher 4 T11-58
317 Bracket 1 ML-746
Metal Chain Container (20 ft [6 m] of chain capacity) order kit HLK-K750-20
318 Metal Chain Container (40 ft [12 m] of chain capacity) 1 order kit HLK-K750-40
Metal Chain Container (80 ft [24 m] of chain capacity) VH3371
--- Stop Ring Assembly 1 MR-A259
319 Stop Ring 1 MR-259
320 Pin 1 34U-215A
321 Setscrew 1 502-95
322 Bolt 4 R3-7A
324 Bolt 2 M0V010AA-634
325 Lockwasher 2 L01-67
326 Nut 2 MR-37

* For pull chain controlled hoists only.

57
 TROLLEY ASSEMBLY INFORMATION

TROLLEYS USED WITH HOISTS PRIOR TO JUNE 1996:

PUSH TYPE HOOK SUSPENSION TROLLEYS
Trolley Part Number Adjustable for Beam Flange Widths For additional
Hoist
information refer to
Capacity For Use on Hoist
Tapered Tread Flat Tread Installation and Parts
Tons inches mm
(I-Beam) (WF-Beam) Form No.
CE120-K426 CE120-K426T HL1000K
1 3.00 to 5.00 76 to 127 P6720
CE120-KR426 CE120-KR426T HL1000KR
HL1500K and
1-1/2 and 2 HRA40A-A700 HRA40A-AT700 3.33 to 6.00 84 to 152 contact factory
HL2000K
3 TP3A-K426 TP3A-K426T HL3000K 3.2 to 5.50 81 to 140 P6723
HL4500K and
4-1/2 and 6 TP6A-K426 TP6A-K426T 3.25 to 7.25 82 to 184 P6744
HL6000K
PUSH TYPE RIGID LUG MOUNT TROLLEYS
Trolley Part Number Adjustable for Beam Flange Widths For additional
Hoist
information refer to
Capacity For Use on Hoist
Tapered Tread Flat Tread Installation and Parts
Tons inches mm
(I-Beam) (WF-Beam) Form No.
CE120-K430 CE120-K430T HL1000K
1 3.00 to 5.00 76 to 127 P6725
CE120-KR430 CE120-KR430T HL1000KR
HL1500K, HL2000K
1-1/2, 2 and 3 TP3A-K430 TP3A-K430T P6719
and HL3000K
3.25 to 7.25 82 to 184
HL4500K and
4-1/2 and 6 TP6A-K430 TP6A-K430T P6743
HL6000K

TROLLEYS USED WITH HOISTS AFTER JUNE 1996:

PUSH TYPE HOOK SUSPENSION TROLLEYS
For additional
Hoist Adjustable for Beam Flange Widths
Part Number information refer to
Capacity For Use on Hoist
(Universal Wheels) Installation and Parts
Tons inches mm Form No.
PT010 HL1000K A = 3.00 to 5.25 76 to 133
1
PT010SB HL1000KR -8 = 3.00 to 8.06 76 to 205
HL1500K and A = 3.33 to 6.00 85 to 152
1-1/2 and 2 PT020 MHD56102
HL2000K -8 = 3.33 to 8.06 85 to 205
A = 4.00 to 6.25 102 to 159
3 PT030 HL3000K
-8 = 4.00 to 8.06 102 to 205
HL4500K and
4-1/2 and 6 TIR132S-P00AH 4.25 to 7.25 108 to 184 MHD56083
HL6000K
PUSH TYPE RIGID LUG MOUNT TROLLEYS *
For additional
Hoist Adjustable for Beam Flange Widths
Part Number information refer to
Capacity For Use on Hoist
(Universal Wheels) Installation and Parts
Tons inches mm Form No.
1 TIR6600B-P00AP HL1000KR
HL1000K, A - 3.25 to 6.00 83 to 152
1, 1-1/2, 2 and D - 6.00 to 12.00 152 to 305
TIR6600S-P00AP HL1500K, HL2000K
3 MHD56083
and HL3000K
HL4500K and
4-1/2 and 6 TIR132S-P00AP 4.25 to 7.25 108 to 184
HL6000K
* Use only with lug mounted hoists.
HOSE TROLLEYS VANE MOTOR DRIVEN TROLLEYS
American Standard I-Beam Beam Flange Width
Part Number
in mm in mm Refer to Installation and Maintenance Manual
D02-8888 3 to 12 76 to 305 2.33 to 5 59 to 127 Form Number P6609 for additional information.
D10-8888 12 and above 305 and above 5 to 8.75 127 to 222
Note: Refer to manufacturer's trolley manuals for allowable beam flange width adjustments.

58
 REPAIR AND CONVERSION KITS

Pendant Conversion Kit: Includes all components necessary to convert a pull chain throttle hoist to pendant control operation.
Part No. MLK-AL269C (04307310) used on all MLK, MLKR, HLK and HLKR hoists. Length of pendant hose must be specified
when ordering. Pendant length is normally 4 ft (1.2 m) shorter than lift.

Pull Chain Conversion Kit: Part No. MLK-K415 for use on all MLK and HLK hoists. Includes all components necessary, except the
pull chains, to convert a pendant throttle hoist to pull chain control operation. Order pull chains separately. See below:
Part No. CA110-B240 (03457769) Pull chain for use on standard HLK hoists. Specify total length of two required pull chains.
Part No. D02-1413 (03170685) Pull chain for use on HL1000KR spark resistant hoists. Specify total length of two required pull
chains.

Valve Chest Conversion Kit: Includes all components necessary to convert valve chests used on hoists with second letter of the serial
number A through G or with second and third letters of the serial number HA, HB or HC to the same style valve chest used on hoists
with second letter of the serial number other than A through G or with second and third letters of the serial number other than HA, HB
or HC.
Part No. MLK-K545B (03835519).

Manual Brake Release Kit: Includes all the components for a manual release brake and/or
200% brake capability.
Part No. MLK-K390 (03721685) for use on all HLK Hoists.

Piped Away Exhaust Kit: Part No. MHLK-KEXH. Refer to Dwg. MHP0914.

Quick-Exhaust Valves: Must be used on all Hoists with Pendant Control when hoses exceed
20 ft (6 m) in length and includes all fittings and clamps. One quick exhaust valve required for
each control hose when length exceeds 20 ft (6 m). Two quick exhaust valves required for each
control hose when length exceeds 50 ft (15 m).
Part No. 20417 (71069579) for all HLK Hoists.
Part No. MR-939 (03195484) for all trolley or crane motor control hoses.

Overhaul Gasket Kit: Includes gaskets, O-rings and seals for HLK Hoists.
Part No. HLK-K445 (03713740).

Valve Chest Kit:

Part No. MLK-VCK1 Kit. Refer to Dwg. TPA958-1.

Brake Kit:
Part No. MLK-ABK1 Kit. Refer to Dwg. TPB704-3.

59
 ACCESSORIES

FILTERS, REGULATORS AND LUBRICATORS

Filter, Regulator and Filter Part Number Lubricator Part Number
Regulator Size
Lubricator Kit Polycarbonate Polycarbonate
Metal Bowl * Part Number Metal Bowl NPTF
Part Number Bowl * Bowl
C28-04-FKG0-28 F20-04-000 F28-04-SK00-28 R28-04-F0G0-28 L28-04-LK00-28 L20-04-G00 1/2
C31-06-G00 F30-06-000 F30-06-G00 R28-06-F0G0-28 L30-06-000 L30-06-G00 3/4
C31-08-G00 F30-08-000 F30-08-G00 R30-08-G00 L30-08-000 L30-08-G00 1
* Polycarbonate Bowls include a metal bowl guard. Metal Bowls include sight gauges
PENDANTS AND AIR HOSES
Description of Part Part No. Notes
Two Motor Pendant HRA-A122C (03709177)
Order hose separately.
Three Motor Pendant HRA-A132C (03709219)
Two Motor Pendant and Hose Assembly MLK-AL122C (04307336)
Specify hose length in feet.
Three Motor Pendant and Hose Assembly MLK-AL132C (04307344)
Precoiled Air Hose 1/2 in x 25 ft (13 mm x 8 m) N12-25B
Precoiled Air Hose 3/4 in x 25 ft (19 mm x 8 m) N34-25B Hose sizes refer to inside diameter (ID).
Precoiled Air Hose 3/4 in x 50 ft (19 mm x 15 m) N34-50B

Description of Accessory Part No.

Yellow Touch-Up Paint FAP-237Y
Crimping Tool ML50K-930AT
Chain Lubricant LUBRI-LINK-GREEN

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 OLD STYLE VALVE CHEST ASSEMBLY DRAWING AND PARTS LIST

Old Style Hoist Valve Chest conversion to New Style

Hoist Valve Chest Information:
Valve Chest Converison Kit Part Number MLK-K545B
New Style Hoist refererences apply to hoists with second letter
of the serial number other than A through G or with second and
third letters other than HA, HB, or HC.
Old Style Hoist refererences apply to hoists with second letter
of the serial number A through G or with second and third
letters HA, HB, or HC.
The following table lists the Old Style Item Number,
Description of Part (with original total quantity) and the
comparable New Style Item Number.
OLD NEW
DESCRIPTION
STYLE STYLE
OF PART
ITEM ITEM
(QTY. TOTAL)
NO. NO.
96 Plug, Pipe - Pull Chain (1) 96
97 Plug, Vent - Pull Chain (2) 97
181 Fitting, Elbow - Pendant (1) 181
182 Fitting, Nipple - Pendant (2) 182
183 Link (1) 183
325 Valve Assembly (2) Not
326 Valve Sleeve Seal (6 ea.) required
327 Valve Spring (2) 9
328 Long Piston Rod (1)
15
329 Short Piston Rod (1)
330 Piston (2) 14
331 Piston Seal (1 ea.) 14A
332 Piston Nut (2) 15B
333 Piston Spring (2) 13
334 Valve Chest Cover (1) 18
335 Valve Chest Cover Seal (2) 18A
336 Bleed Adjustment Screw (2) 19
337 Adjustment Screw Locknut (2) 21
338 Valve Chest Cover Gasket (1) 16
339 Valve Chest Cover Screw (6) 22

NOTICE
• Parts for old style valve chest are no longer available.
Order Conversion Kit MLK-K545B.
This table provides a comparison between the Old Style Hoist
Valve Chest parts and the New Style Hoist Valve Chest parts to
assist in installing the conversion kit. Refer to Dwg. TPA958-1
for New Style Hoist Valve Chest part numbers. Do not replace
individual Old Style Hoist Valve Chest parts with New Style
Hoist Valve Chest Parts. To repair an Old Style Hoist Valve
Chest order the Valve Chest Conversion Kit (MLK-K545B) and
replace all parts.

61
 PARTS ORDERING INFORMATION

HLK Hoists are designed and constructed to provide long, Return Goods Policy
trouble-free service. In time it may become necessary to order If it becomes necessary to return the complete hoist or certain
and install new parts to replace those that have been subjected to parts to the factory, contact the distributor from whom you
wear. purchased the hoist, or the nearest Ingersoll-Rand distributor in
The use of other than Ingersoll-Rand Material Handling your locality.
replacement parts may result in decreased hoist performance,
and may, at the company’s option invalidate the warranty. For Ingersoll-Rand will not accept any returned goods for warranty
prompt service and genuine Ingersoll-Rand Material Handling or service work unless prior arrangements have been made and
parts, provide your nearest distributor with the following: written authorization has been provided from the location where
the goods were purchased.
1. Complete hoist model number and serial number as it
appears on the nameplate.
2. Part number and part description as shown in this manual. NOTICE
3. Quantity required.
• Continuing improvement and advancement of design may
The serial number label is located on the hoist housing. cause changes to this hoist which are not included in this
manual. Manuals are periodically revised to incorporate
changes. Always check the manual edition number on the
front cover for the latest issue.

Disposal
When the life of the hoist has expired, it is recommended that
the hoist be disassembled, degreased and parts separated as to
The model number label is located on the hoist housing. materials so that they may be recycled.

NOTICE
• Mineral based oils can be recycled, however, some oils such
as glycols may be extremely toxic and must be identified and
disposed of in accordance with local, state and national
regulations.

For your convenience and future reference it is recommended For additional information contact:
Ingersoll-Rand Material Handling
that the following information be recorded.
1725 U.S. Highway #1-N
Southern Pines, NC 28387 USA
Hoist Model Number __________________________________
Phone: (910) 692-8700
Fax: (910) 692-7822
Hoist Serial Number __________________________________
or
Date Purchased ______________________________________
Ingersoll-Rand International Sales
Swan Lane, Hindley Green,
Wigan WN2 4EZ U.K.
Phone: (44) 1942-257131
Fax: (44) 1942-526255

For additional information on the following products order the Publication by the referenced Part/Document Number listed:

Publication Part/Document No.

TIR Trolley MHD56083
PT/RT Trolley MHD56102
TP3A-K430 and TP3A-K430T P6719
CE120-K426 and CE120-K426T P6720
TP3A-K426 and TP3A-K426T P6723
CE120-K430 and CE120-K430T P6725
TP6A-K430 and TP6A-K430T P6743
TP6A-K426 and TP6A-K426T P6744
MLK Hoist P6554
HRA40A-A700 and HRA40A-AT700 contact factory

62
 WARRANTY

LIMITED WARRANTY
Ingersoll-Rand Company (I-R) warrants to the I-R makes no other warranty, and all implied
original user its Hoists and Winches (Products) to be warranties including any warranty of
free of defects in material and workmanship for a merchantability or fitness for a particular purpose
period of one year from the date of purchase. I-R will are limited to the duration of the expressed warranty
repair, without cost, any Product found to be period as set forth above. I-R’s maximum liability is
defective, including parts and labor charges or, at its limited to the purchase price of the Product and in
option, will replace such Products or refund the no event shall I-R be liable for any consequential,
purchase price less a reasonable allowance for indirect, incidental, or special damages of any nature
depreciation, in exchange for the Product. Repairs or rising from the sale or use of the Product, whether
replacements are warranted for the remainder of the based on contract, tort, or otherwise.
original warranty period.
Note: Some states do not allow limitations on
If any Product proves defective within its original one incidental or consequential damages or how long an
year warranty period, it should be returned to any implied warranty lasts so the above limitations may not
Authorized Hoist and Winch Service Distributor, apply to you.
transportation prepaid with proof of purchase or
warranty card. This warranty gives you specific legal rights and you
may also have other rights which may vary from state to
This warranty does not apply to Products which I-R state.
has determined to have been misused or abused,
improperly maintained by the user, or where the
malfunction or defect can be attributed to the use of
non-genuine I-R parts.

IMPORTANT NO
IMPORT TICE
NOTICE
It is our policy to promote safe delivery of all orders. or container, loss or damage has taken place while in
This shipment has been thoroughly checked, packed transit, notify the carrier’s agent immediately.
and inspected before leaving our plant and receipt for
it in good condition has been received from the Damage Claims
carrier. Any loss or damage which occurs to this You must file claims for damage with the carrier. It is
shipment while enroute is not due to any action or the transportation company’s responsibility to
conduct of the manufacturer. reimburse you for repair or replacement of goods
damaged in shipment. Claims for loss or damage in
Visible Loss or Damage shipment must not be deducted from the
If any of the goods called for on the bill of lading or Ingersoll-Rand invoice, nor should payment of
express receipt are damaged or the quantity is short, Ingersoll-Rand invoice be withheld awaiting
do not accept them until the freight or express agent adjustment of such claims as the carrier guarantees safe
makes an appropriate notation on your freight bill or delivery.
express receipt.
You may return products damaged in shipment to us
Concealed Loss or Damage for repair, which services will be for your account and
When a shipment has been delivered to you in form your basis for claim against the carrier.
apparent good condition, but upon opening the crate

63
 United States Office Locations International Office Locations

For Order Entry, Order Regional Sales Offices Offices and distributors in British Columbia
Status and Technical principal cities throughout 201-6351 Westminster Hwy
Support Chicago the world. Contact the Richmond, B. C.
888 Industrial Drive nearest Ingersoll-Rand V7C 5C7
Ingersoll-Rand Elmhurst, IL 60126 office for the name and Phone: (604) 278-0459
Material Handling Phone: (630) 530-3800 address of the distributor in Fax: (604) 278-1254
1725 U.S. Highway #1-N Fax: (630) 530-3891 your country or write/fax to:
Southern Pines, NC 28387 Latin America Operations
Phone: (910) 692-8700 Detroit, MI Ingersoll-Rand Ingersoll-Rand
Fax: (910) 692-7822 23192 Commerce Drive Material Handling Production Equipment Group
Farmington Hills, MI 48335 1725 U.S. Highway #1-N 730 N.W. 107 Avenue
Ingersoll-Rand Phone: (810) 476-6677 Southern Pines, NC 28387 Suite 300, Miami, FL
Distribution Center Fax: (810) 476-6670 USA 33172-3107
P.O. Box 618 Phone: (910) 692-8700 Phone: (305) 559-0500
510 Hester Drive Houston, TX Fax: (910) 692-7822 Fax: (305) 559-7505
White House, TN 37188 Suite 150
Phone: (615) 672-0321 2500 East T.C. Jester Canada Europe, Middle East and
Fax: (615) 672-0801 Houston, TX 77008 National Sales Office Africa
Phone: (713) 864-3700 Regional Warehouse Ingersoll-Rand
Fax: (713) 864-2244 Toronto, Ontario Swan Lane, Hindley Green,
51 Worcester Road Wigan WN2 4EZ U.K.
Los Angeles, CA Rexdale, Ontario Phone: (44) 1942-257131
11909 E. Telegraph Road M9W 4K2 Fax: (44) 1942-526255
Santa Fe Springs, CA 90670 Phone: (416) 213-4500
Phone: (310) 948-4189 Fax: (416) 213-4510
Fax: (310) 948-1828 Order Desk Asia Pacific Operations
Fax: (416) 213-4605 Ingersoll-Rand (Japan) Ltd.
Philadelphia, PA Shin-Yokohama Square Bldg.
P.O. Box 425 Regional Sales Offices (5TH Floor)
900 E. 8th Ave., Suite 103 2-3-12 Shin-Yokohama,
King of Prussia, PA 19406 Calgary, Alberta Kouhoku-Ku, Yokohama-shi,
Phone: (610) 337-5930 44 Harley Road S.E. Kanagawa Pref. 222 Japan
Fax: (610) 337-5912 Calgary, Alberta Phone: 81-45-476-7800
T2V 3K3 Fax: 81-45-476-7806
Phone: (403) 252-4180
Fax: (403) 252-4462 Russia
Ingersoll-Rand Company
Edmonton, Alberta Kuznetsky Most 21/5
1430 Weber Center Moscow 103895 Russia
5555 Calgary Trail N.W. Phone: 7 501 921 53 21
Edmonton, Alberta 7 501 923 91 34
T6H 5G8 Fax: 7 501 924 46 25
Phone: (403) 438-5039
Fax: (403) 437-3145

Montreal, Quebec
3501 St. Charles Blvd.
Kirkland, Quebec
H9H 4S3
Phone: (514) 695-9040
Fax: (514) 695-0963

Printed in USA

64